Duct Flange Assembly With Pre-Formed Fastener Entry Areas
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Solution Overview
Problem
Existing methods for attaching flanges to duct members are inefficient due to the need for significant pressure and torque to pass fasteners through multiple layers of sheet metal, leading to potential injury, deformation of components, and a lack of a tight fit, which complicates the assembly process and increases costs.
Innovation Solution
The use of pre-fabricated fastener entry areas, such as through holes or indentations, on both sides of the flange and duct member allows for easier and more secure attachment with reduced force and torque requirements, preventing deformation and ensuring a tight fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fasteners are passed through multiple layers of sheet metal using significant pressure and torque, then secure attachment is achieved, but component deformation and assembler injury occur
Solution Approach 1:
The patent applies preliminary action by pre-forming recesses in the flange portions before assembly. These recesses are created during manufacturing, so that when fasteners are inserted during assembly, they engage with the pre-prepared recesses rather than requiring forceful penetration through multiple metal layers. This eliminates the need for high pressure and torque during assembly, preventing both component deformation and assembler injury while still achieving secure attachment.
2Reliability
If fasteners are inserted through multiple sheet metal layers, then flange attachment is achieved, but assembly time and complexity increase
Solution Approach 1:
The recesses are pre-formed in the flange portions during manufacturing, eliminating the need for现场 drilling or forceful fastener insertion. Assemblers simply need to insert fasteners into the pre-prepared recesses, which dramatically reduces assembly time while maintaining reliable attachment. The pre-formed recesses guide fastener placement and ensure proper engagement without requiring complex alignment procedures.
3Strength
If significant force is applied to pass fasteners through metal layers, then secure connection is achieved, but material deformation occurs
Solution Approach 1:
The recesses are precisely formed during flange manufacturing with accurate dimensions and positions. When fasteners are inserted into these pre-formed recesses, they engage without requiring forceful penetration, thereby preventing deformation of the flange portions or duct members. This maintains the dimensional accuracy and structural integrity of all components while still achieving strong connections through proper fastener engagement with the recesses.
Data Source
AI summary
A flange to be assembled to a duct member includes a plurality of pre-fabricated apertures or areas of weakened wall strength for receiving fasteners to assemble the flange to the end of a duct member. The apertures may be spaced apart such that the fasteners can be inserted at regular intervals along the length of the flange and the length of the end of the duct member.