Ducting systems
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Solution Overview
Problem
Existing ducting systems for air distribution require costly and hazardous installation of thermal insulation, with risks of gaps, condensation, and reduced productivity due to high placement and accessibility issues.
Innovation Solution
A duct section with an elongate frame and thermal insulation lining, where the insulation is integrated during manufacturing, ensuring a continuous and sealed insulation when sections are joined, using a tubular element with flanges and secured by mastic adhesive and gaskets, allowing for easier assembly and quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermal insulation is installed after ducting erection, then the ducting system can be assembled first, but worker safety deteriorates due to high placement requiring scaffolding
Solution Approach 1:
The patent combines the thermal insulation layer and ducting structure into a single integrated unit. The insulation is pre-installed on the ducting sections before erection, merging two separate installation processes (ducting assembly and insulation installation) into one, thereby eliminating the need for scaffolding and improving worker safety while maintaining manufacturing efficiency
Solution Approach 2:
The thermal insulation is applied to the ducting sections before they are erected into the final configuration. This preliminary action allows workers to install insulation at ground level in a controlled environment, then assemble the pre-insulated ducting sections using standard connection methods, avoiding high-altitude insulation installation
2Ease of manufacture
If thermal insulation is installed after ducting erection, then the ducting system can be assembled first, but installation cost deteriorates due to scaffolding requirements
Solution Approach 1:
By merging ducting assembly and insulation installation into a single integrated process, the patent eliminates the need for expensive scaffolding equipment and reduces installation time. The pre-installed insulation allows for streamlined assembly using standard connection methods, significantly reducing overall installation costs
3Ease of manufacture
If thermal insulation is installed after ducting erection, then the ducting system can be assembled first, but installation quality deteriorates with gaps and condensation risks
Solution Approach 1:
The thermal insulation is applied to ducting sections in a controlled factory environment before erection, allowing for precise and uniform installation. This preliminary action ensures consistent insulation thickness and proper sealing at connection points, eliminating gaps that would lead to condensation and thermal loss
Solution Approach 2:
The integrated design ensures that the insulation layer continuously covers the ducting surface including connection areas. The merging of insulation and ducting into a single unit guarantees uniform thermal protection throughout the entire system, preventing cold spots and condensation formation
4Ease of manufacture
If workers install thermal insulation at high placement, then the ducting system can be erected first, but productivity deteriorates due to difficult working conditions
Solution Approach 1:
The thermal insulation is installed on ducting sections at ground level in a controlled environment before erection. Workers can perform this task efficiently with proper tools and equipment, then the pre-insulated sections are assembled using standard connection methods, dramatically improving productivity compared to high-altitude insulation installation
5Ease of manufacture
If thermal insulation is installed after ducting erection, then the ducting system can be assembled first, but accessibility deteriorates in certain areas
Solution Approach 1:
The thermal insulation is applied to ducting sections before they are erected into difficult-to-reach positions. This preliminary action allows insulation installation to occur in accessible ground-level conditions, then the complete units are positioned in hard-to-reach areas, solving the accessibility problem
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 solution reduces installation costs and risks, ensures accurate and uniform insulation, and minimizes the risk of cold spots and condensation, while improving worker safety and productivity by allowing factory-controlled assembly.
Implementation Method 1
each duct section is lined with a thermal insulating material to provide a thermally insulating lining to the air passage
Implementation Method 2
the lining material is secured to the duct by a mastic adhesive
Implementation Method 3
an air gap may be formed between the inner surface of the duct and the insulating lining
Implementation Method 4
the end faces of the insulating lining which abut when two sections are joined, are sealed with a foil tape or hardcast seal
Data Source
AI summary
The invention discloses a duct section for an air distribution system, the duct sections including an elongate frame having two opposed flange members each having an opening forming an air passage therein. A plurality of the duct sections are able to be joined together through the flanges to form an air passage of desired length. Each duct section is lined with a thermal insulating material to provide a thermally insulating lining to the air passage, the ends of the lining being at least flush with the end faces of the flanges so that when adjacent duct sections are secured together, the thermal insulation lining of adjacent duct sections is arranged to provide a continuous insulating lining of the air passage.