Composite Grille Assembly for Rust-Free Aesthetic Airflow Control
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Solution Overview
Problem
Conventional air duct grilles are often made of metal, which can rust and collect dust, and lack aesthetic appeal, making them undesirable for integration with building décor.
Innovation Solution
A grille assembly comprising a grille plate with airflow cutouts, an airflow regulator, and an inner mounting plate, using fastening and spacer components like female rivet fasteners and shoulder washers to create a clearance space, allowing for customizable design and mounting over air duct openings, with options for materials like acrylic and Dibond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional metal grilles are used, then structural strength is maintained, but aesthetic appeal deteriorates and dust accumulation increases
Solution Approach 1:
The grille plate is constructed from composite materials (acrylic and/or Dibond) instead of conventional metal, combining aesthetic appeal with durability and dust resistance while maintaining structural integrity through the composite nature of the material
Solution Approach 2:
The grille plate incorporates localized decorative elements and patterns (such as wave patterns, geometric designs, or custom artwork) in specific areas to enhance aesthetic appeal without compromising the overall structural function or dust resistance of the entire grille assembly
2Duration of action of stationary object
If metal grilles are used, then durability is maintained, but rust resistance deteriorates
Solution Approach 1:
The grille plate utilizes composite materials (acrylic and/or Dibond) that inherently resist rust and corrosion, providing long-term durability without the rust issues associated with metal grilles, while maintaining structural strength through the composite material properties
3Ease of manufacture
If a simple grille design is used, then manufacturing ease is maintained, but aesthetic integration with décor deteriorates
Solution Approach 1:
The grille plate is made from composite materials that can be easily fabricated into various decorative patterns and designs, allowing for aesthetic integration with different décor styles while maintaining manufacturing efficiency through standard composite material processing techniques
Solution Approach 2:
The grille plate incorporates localized decorative elements and patterns (such as wave patterns, geometric designs, or custom artwork) in specific areas to enhance aesthetic appeal without compromising the overall structural function or manufacturing simplicity of the entire grille assembly
4Device complexity
If grille plate is mounted directly to mounting plate, then structural simplicity is maintained, but airflow regulation effectiveness deteriorates
Solution Approach 1:
The mounting structure is segmented into distinct components (grille plate, mounting plate, and fastening mechanism) that work together to provide both structural simplicity and effective airflow regulation, with each component having a specific function in the overall system
Solution Approach 2:
The fastening mechanism acts as an intermediary between the grille plate and mounting plate, providing a controlled connection that maintains structural simplicity while enabling effective airflow regulation through the integrated design of the fastening components
Data Source
AI summary
Disclosed is a grille assembly, which may comprise a grille plate including airflow cutouts within the grille plate, and may be designed to integrate with, or enhance the décor of a room. In certain embodiments, the grille assembly may further comprise an airflow regulator including a main body configured to insert into an airduct opening within a building structure, and the grille plate is configured to mount to a surface of the building structure over the airduct opening and airflow regulator inserted therein.