Corner Flange Connection for Duct Assembly Without Drift Pins
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Solution Overview
Problem
Existing methods for assembling and hanging duct sections on job sites are inefficient, labor-intensive, and prone to errors, leading to leaks, safety hazards, and increased costs due to the use of drift pins, adhesive gaskets, and conventional fasteners, which are cumbersome and imprecise.
Innovation Solution
The use of large sheet metal screws through alignable holes in opposing inserted corner plates to align and secure duct sections, allowing for easy alignment and assembly without the need for additional clamps or drift pins, and enabling the incorporation of hangers directly into the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If drift pins and adhesive gaskets are used for aligning and sealing duct sections, then alignment and sealing can be achieved, but the process becomes labor-intensive, time-consuming, and prone to errors causing leaks
Solution Approach 1:
The patent combines alignment holes and sealing gaskets into an integrated unit. The gasket is positioned within the alignment hole structure, eliminating the need for separate drift pins and adhesive gasket application. This merged design allows workers to align and seal duct sections simultaneously in a single operation, dramatically improving assembly speed while maintaining connection reliability through the unified structure.
Solution Approach 2:
The alignment hole assembly serves multiple functions: it provides alignment guidance, structural connection, and sealing in one component. The gasket-integrated alignment hole replaces multiple separate tools and materials (drift pin for alignment, adhesive gasket for sealing), making the system more efficient and reducing the number of steps required for duct section assembly.
2Reliability
If multiple separate components (drift pins, clamps, adhesive gaskets) are used for duct assembly, then alignment and sealing can be achieved, but device complexity and labor requirements increase
Solution Approach 1:
The patent merges the gasket material directly into the alignment hole structure, creating a single integrated component that performs both alignment and sealing functions. This eliminates the need for separate drift pins, clamps, and adhesive gasket applications, reducing device complexity while maintaining sealing effectiveness through the unified design.
Solution Approach 2:
The alignment hole assembly is designed to perform multiple functions simultaneously: providing mechanical alignment, structural support, and sealing. This multi-functional design reduces the total number of components needed in the assembly process while ensuring reliable sealing through the integrated gasket structure.
3Strength
If conventional fasteners and separate hangers are used for duct assembly and hanging, then structural support can be achieved, but the assembly process becomes more time-consuming and labor-intensive
Solution Approach 1:
The corner plate is designed to serve dual purposes: providing structural reinforcement for the duct joint and serving as an attachment point for hangers. The integrated hanger attachment features are built into the corner plate structure itself, allowing workers to assemble duct sections and attach hanging supports in the same operation, significantly reducing assembly time while maintaining full hanging capacity.
Solution Approach 2:
The patent combines the corner plate reinforcement and hanger attachment into a single integrated component. Instead of using separate corner plates and separate hanger brackets, the hanger attachment features are built into the corner plate structure, allowing simultaneous fulfillment of structural and hanging functions in one element.
Data Source
AI summary
A corner flange connection member configured for joining together adjacent duct channel flanges associated with duct sections includes two leg portions joined together in angular relationship by a corner portion, and at least one opening in said corner portion for receiving at least one fastening member for connecting said corner flange connection member to the duct sections. The at least one opening is shaped so as to threadably receive the fastening member without cutting threads.