Duct Flange Corner Inserts for Low-Labor HVAC Suspension
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Solution Overview
Problem
Existing methods for supporting rectangular metal ducts in HVAC systems are costly and can compromise structural integrity, with steel wire potentially cutting into ducts and cradle bars requiring custom cutting, leading to increased labor and material expenses.
Innovation Solution
A method and apparatus for connecting elongate air transport ducts to supports using a plurality of support members, featuring flanges with receiving channels and insertable corner members that form load-bearing connections, allowing for secure attachment without the need for custom cutting or high labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If steel wire is used to directly support the duct, then the support method is simple, but the steel wire can cut into the sheet metal wall of the duct
Solution Approach 1:
The patent introduces an intermediary component (support channel or cradle bar) between the steel wire and the duct wall. The steel wire supports the support channel from below, which in turn supports the duct, preventing direct contact and potential damage to the duct wall while maintaining structural integrity.
2Reliability
If cradle bars are used to support the duct, then the duct is supported from below, but the cradle bars require custom cutting to match duct width, increasing labor costs
Solution Approach 1:
The support channel is designed with a universal geometry (such as a C-shaped cross-section) that can accommodate various duct widths without requiring custom cutting. The channel's open end allows it to flexibly fit different duct sizes, making a single standard component suitable for multiple applications.
Solution Approach 2:
The support system is segmented into modular components: standardized support channels and adjustable positioning elements. This segmentation allows the channels to be manufactured in standard sizes while still adapting to different duct widths through the use of adjustable fasteners or positioning blocks, eliminating the need for custom cutting.
3Reliability
If threaded rods with cradle bars are used, then the duct is securely supported, but long supporting steel wire or rod must be deployed to reach the bottom surface, increasing material usage
Solution Approach 1:
The support channel provides a horizontal support surface that extends across the duct width, allowing threaded rods to connect at multiple points along the channel's length. This dimensional extension enables shorter vertical support members to be used, as the load is distributed across the channel structure rather than requiring single long rods to reach the entire duct bottom surface.
Data Source
AI summary
An air transport duct, and sections of such duct, capable of connection to a support by support members and attachment members formed from two mating members. Each section has two terminal open ends and a flange disposed around each open end for connection to a flange of an adjacent section. Each flange includes two relatively transverse receiving channels adjacent to a corner of the flange, and an insertable corner member positioned into the channels. The corner member is attached to the flange by a load-bearing connection, and can support a predetermined portion of a weight of the duct by connection of the corner member to a first mating member connectable to a second mating member secured to a corresponding support member. A method of connecting a duct to a support by forming a load-bearing connection between a corner member and a flange.