Inserted Corner Members for Load-Bearing HVAC Duct 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, increasing labor costs and installation complexity.
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 wire can cut into the sheet metal wall of the duct
Solution Approach 1:
The patent introduces corner members as intermediary elements between the support wire/rod and the duct flange. These corner members distribute the concentrated load from the support across multiple attachment points on the flange, preventing the wire from cutting into the duct wall while maintaining structural integrity.
Solution Approach 2:
The corner members are strategically positioned at the corners of the duct flange where support is most needed. By concentrating reinforcement at these critical local points rather than uniformly across the entire flange, the solution prevents damage where it matters most while minimizing material usage.
2Reliability
If cradle bars are used to support the duct, then the duct is supported from below, but the cradle bars must be cut to size increasing labor costs
Solution Approach 1:
The corner members are designed as universal components that can be used with ducts of various sizes and support configurations. Instead of custom-cutting cradle bars for each duct size, the same corner member design can accommodate different applications by adjusting the number and positioning of supports, eliminating the need for custom fabrication.
Solution Approach 2:
The support system is segmented into standardized corner members that can be independently installed at each duct corner. This modular approach allows for easier assembly and adjustment compared to continuous cradle bars, reducing installation labor while maintaining reliable support.
3Reliability
If threaded rods with cradle bars are used, then the duct is supported securely, but long supporting steel wire or rod must be deployed increasing material costs
Solution Approach 1:
The corner members transfer support loads from a single-point suspension model to a distributed multi-point attachment model. By attaching supports to multiple corners of the duct flange rather than using long wires spanning the entire duct, the system achieves secure support with shorter support elements, reducing material quantity.
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.