Curved Foam Duct Pre-Form With Intact Facing Layers
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Solution Overview
Problem
Conventional insulation methods for circular ductworks in thermal distribution systems often result in significant thermal losses due to inadequate manufacturing processes, which fail to effectively form and maintain insulation without damaging protective layers.
Innovation Solution
A duct pre-form configured with a layer of foam insulative material and facing layers, featuring spaced-apart depressions formed without breaking or marring the continuity of the facing layers, is manufactured using a forming fixture that controls depression spacing, depth, and bend angle based on foam density and elastomeric properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional foam-based panels are cut and bent into circular shapes, then circular duct insulation can be formed, but the facing layers are broken, torn, or ripped during the process
Solution Approach 1:
The patent applies preliminary action by pre-forming depressions in the foam insulation panel before bending. The forming die creates spaced-apart depressions that allow the panel to be bent into a circular shape without breaking the facing layers. This preliminary structuring of the foam panel enables subsequent bending while maintaining facing layer integrity.
2Ease of manufacture
If foam-based panels are shaped for circular ducts using conventional methods, then the duct insulation can be installed, but thermal losses increase due to inadequate insulation formation
Solution Approach 1:
The patent applies parameter changes by controlling the depth, spacing, and geometry of depressions formed in the foam insulation panel. By optimizing these parameters based on the foam's density and elastomeric properties, the panel achieves proper curvature when bent, ensuring continuous insulation coverage without gaps or defects that would cause thermal losses.
3Shape
If the foam panel is compressed to form depressions, then the panel can be bent into curve, but the facing layers may be damaged
Solution Approach 1:
The patent applies local quality by forming localized depressions in specific areas of the foam panel rather than uniformly compressing the entire panel. The spaced-apart depressions are strategically positioned to create the necessary curvature while leaving the facing layers in non-depression areas undamaged and intact.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances the insulation efficiency by forming curved ducts with precise geometry, reducing thermal losses and maintaining the integrity of protective layers, thereby improving the overall performance of thermal distribution systems.
Implementation Method 1
compressing the duct board with the forming die in a manner such as to form a first depression in the layer of foam insulation material
Implementation Method 2
a layer of foam insulative material
Data Source
AI summary
A duct pre-form configured for forming a section of curved duct is provided. The duct pre-form includes a layer of foam insulative material. The layer of foam insulative material has a first and second major side. A first facing layer is attached to the first major side of the foam insulative material. A second facing layer is attached to the second major side of the foam insulative material. A plurality of depressions is formed in one of the major sides of the layer of foam insulative material and one of the first or second facing layers. The plurality of depressions is formed without breaking, tearing, ripping or otherwise marring the continuity of the first or second facing layers.