Expandable plenum flange and method of use

Solution Overview

Problem

Existing flanges in HVAC duct systems pose safety hazards during installation due to sharp edges and are difficult to reposition after installation, as the radial tabs become inaccessible once duct work is attached.

Innovation Solution

A laterally disposed toggle mechanism is positioned on the exterior surface of a cylindrical flange, allowing it to expand and contract for easy positioning and repositioning within a plenum hole, while preventing injury from sharp edges.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If radial tabs are bent outward to secure the flange in the plenum hole, then the flange is held firmly in place, but the installer is exposed to sharp edges causing injury

Engineering Contradiction:

Improveflange securingVSAvoidsharp edge injury

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The toggle mechanism inverts the traditional tab orientation by positioning the expansion mechanism on the exterior surface rather than having tabs bend outward inward. This allows the flange to be secured without exposing the installer to sharp edges, as the expansion action occurs externally through the toggle mechanism.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The toggle mechanism acts as an intermediary between the installer and the flange expansion process. Instead of directly manipulating sharp tabs, the installer operates the toggle mechanism which then mediates the expansion of the flange edges, eliminating direct contact with harmful sharp edges.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If radial tabs are positioned inside the plenum to secure the flange, then the flange is held firmly, but repositioning becomes difficult after duct work is attached

Engineering Contradiction:

Improveflange securingVSAvoidrepositioning

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The toggle mechanism inverts the traditional tab orientation by positioning the expansion mechanism on the exterior surface rather than having tabs bend outward inward. This allows the flange to be secured without exposing the installer to sharp edges, as the expansion action occurs externally through the toggle mechanism.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The toggle mechanism provides dynamic control over the flange expansion state. The flange can be easily transitioned between expanded and collapsed states by operating the toggle, enabling simple repositioning even after duct work is attached, as the mechanism remains accessible from the exterior.

Inventive Principle:

Principle #15Dynamics

3Reliability

If the flange is expanded to seal against the plenum chamber, then air leakage is prevented, but the flange cannot be repositioned after installation

Engineering Contradiction:

Improveair sealVSAvoidrepositioning

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The toggle mechanism provides dynamic control over the flange expansion state. The flange can be easily transitioned between expanded and collapsed states by operating the toggle, enabling simple repositioning even after duct work is attached, as the mechanism remains accessible from the exterior.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The toggle mechanism is designed to be self-contained and self-operating on the exterior surface. The installer can independently control the expansion and collapse of the flange without needing to access the interior of the plenum, allowing the system to serve itself for repositioning operations.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS12339029B2Expandable plenum flange and method of use

Publication Date: 2025.06.24 BENOIT CHRISTOPHER HENRY

AI summary

An expandable plenum flange for a heating ventilating and air conditioning system is provided. The flange includes a toggle mechanism positioned on its exterior surface. The toggle mechanism provides a multi-jointed closure having an open position and a closed position. The open position contracts the diameter and circumference of the flange. The closed position expands the circumference and diameter of the flange thereby sealing it in a plenum hole.