Duct Corner Support Assembly for Fast 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 lengths, increasing labor and material costs.
Innovation Solution
A method and apparatus using a plurality of support members with load-bearing connections between corner members and channels in duct sections, allowing for secure attachment to supports without the need for custom lengths or crimping, utilizing metal formed load-bearing connections and two-piece attachment members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If steel wire is used to directly support the duct by encircling it, then the support method is simple to implement, but the wire can cut into the sheet metal wall of the duct depending on weight considerations
Solution Approach 1:
The patent introduces an intermediary component (support channel or cradle bar) between the steel wire and the duct. The wire supports the channel rather than directly encircling the duct, and the channel in turn supports the duct. This intermediary distributes the wire tension across a larger surface area of the duct, preventing the wire from cutting into the sheet metal wall while maintaining the simplicity of wire-based support.
2Reliability
If cradle bars are used to support the duct from below, then the duct is securely supported, but the lengths of cradle bars must be cut to size to correspond to the width of the particular ductwork, increasing labor costs
Solution Approach 1:
The patent makes the cradle bar universal by designing it with adjustable positioning mechanisms. The cradle bar can be manufactured in standard lengths and then adjusted during installation to accommodate different duct widths through movable support points or adjustable mounting positions. This eliminates the need to cut each cradle bar to custom sizes while maintaining secure support for various duct configurations.
Solution Approach 2:
The cradle bar incorporates dynamic adjustment capabilities, allowing its effective span and positioning to be modified during installation. This could include telescopic sections, movable support arms, or adjustable mounting brackets that enable a single cradle bar design to adapt to different duct dimensions without requiring custom cutting, thereby improving installation efficiency while maintaining structural reliability.
3Reliability
If threaded rods are used in conjunction with cradle bars, then the duct is supported from below, but the lengths of supporting steel wire or rod must be long enough to reach the bottom supported surface of the affected ductwork
Solution Approach 1:
The patent transitions from vertical-only support to multi-dimensional support by introducing cradle bars that extend horizontally beneath the duct. Instead of relying solely on long vertical wires/rods reaching from the ceiling to the duct bottom, the cradle bar creates a horizontal support plane that intercepts the duct earlier, allowing shorter vertical support elements to be used. This dimensional change reduces the required length of supporting wire or rod while maintaining support stability.
Data Source
AI summary
A unitary support assembly for connecting an air transport duct to a support includes a body portion, a duct connecting means integrally formed with the body portion for selectively securing the support assembly to the air transport duct, and a support connecting means integrally formed with the body portion opposite the duct connecting means for selectively securing the support assembly to the support.