Double wall duct connector
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Solution Overview
Problem
Existing connectors for double wall round and oval duct segments face challenges in maintaining a secure connection without deforming the duct shape and leaking air, especially when ducts have varying dimensions or require heat for installation, which can melt sealant materials.
Innovation Solution
The solution involves using outer and inner duct connectors with transverse flanges and a closure ring, where an adhesive is applied to the flange faces for a self-sealing connection, maintaining the duct shape and providing a universal, tool-free design that adapts to different diameters without heat application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid continuous double-flanged connectors are used to connect double wall duct segments, then connection rigidity is improved, but it becomes difficult to provide a good connection between ducts having different cross-sectional dimensions due to tolerance variations
Solution Approach 1:
The connector is divided into an outer flange and an inner flange that are separate and not connected to each other. The outer flange connects to the outer ducts while the inner flange connects to the inner ducts, allowing independent adaptation to different dimensions. This segmentation enables the connector to accommodate tolerance variations and different cross-sectional dimensions while maintaining connection rigidity through the dual-flange structure.
2Ease of operation
If non-flanged connectors are used to connect circular or oval adjacent duct segments, then ease of installation is improved, but the resulting connection may result in the bending or loss of shape at the connection
Solution Approach 1:
The flanges are designed with curved outer perimeters that substantially circumscribe the cross-section of the ducts, maintaining the round or oval shape at the connection. The inner flange has an outer perimeter that substantially circumscribes the inner duct cross-section, while the outer flange has an outer perimeter that substantially circumscribes the outer duct cross-section, preventing bending and shape loss.
3Strength
If heat is used to attach connectors to duct work segments, then connection strength is improved, but it may result in the melting or dripping of the sealant material
Solution Approach 1:
The invention replaces the thermal attachment process (welding) with a mechanical attachment process using flanges and fastening methods. The outer flange and inner flange provide mechanical connection through bolts, clips, or other fasteners, eliminating the need for heat application and preventing sealant melting or dripping while maintaining connection strength.
4Manufacturing precision
If connectors are designed for specific duct dimensions, then manufacturing precision is improved, but device complexity increases when accommodating varying duct dimensions
Solution Approach 1:
The connector design with separate outer and inner flanges creates a universal connector that can accommodate various duct dimensions and tolerance variations. The outer flange adapts to outer duct dimensions while the inner flange adapts to inner duct dimensions, allowing a single connector design to serve multiple duct size applications without increasing overall device complexity.
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 ensures a leak-proof, shape-maintaining connection capable of withstanding significant pressure differences and accommodating varying duct dimensions, reducing air leakage and installation complexity.
Implementation Method 1
An adhesive is dispensed on the transverse flange face of the inner transverse flange... the transverse flange face of the inner transverse flange and the transverse flange mating face of the outer transverse flange being maintained in contact by the adhesive
Data Source
AI summary
A double wall round or oval duct system assembly having an outer duct connector, an inner duct connector and a closure ring is provided. The inner duct connector of the duct assembly has an adhesive applied on the transverse flange face of its transverse flange thus allowing a sealing connection between the inner and outer duct connectors upon compression with the closure ring. The double wall round or oval duct system assembly will improve the efficiency and will reduce or eliminate air leakage upon connection of two round or oval duct segments. A method of installing the assembly system is also provided.