Flexible Duct Sleeve Radial Compression for Compact Packaging
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Solution Overview
Problem
The high cost of storing and shipping flexible ducting for HVAC systems is exacerbated by the need for axial compression, which can damage components and limits the volume efficiency of packaging, leading to increased storage and shipment costs.
Innovation Solution
Radial compression and rolling of the flexible duct's sleeve with a flattened air core, allowing for more efficient packaging and reduced damage during transport, enabling up to 100% more ducting to be packed in the same volume compared to axial compression methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If axial compression is used to package flexible ducting, then the ducting can be compacted for shipping, but the compression is limited by components that can be damaged and volume efficiency is reduced
Solution Approach 1:
The patent transitions from axial compression (one-dimensional) to radial compression (changing to a different dimension). By compressing the ducting radially outward from the central cavity rather than axially end-to-end, the system achieves greater compression ratios without damaging internal components like the vapor barrier and insulating layer, thereby resolving the contradiction between packaging volume and component reliability
Solution Approach 2:
Instead of compressing the ducting in the conventional axial direction, the patent inverts the approach by compressing radially from the center outward. This inversion allows the rigid structural support to protect internal components during radial compression while achieving superior volume reduction, thus improving packaging efficiency without compromising component integrity
2Volume of moving object
If axial compression is used to reduce packaging volume, then shipping space is optimized, but storage and shipment costs increase due to limited compression capacity
Solution Approach 1:
By switching from axial to radial compression, the patent enables significantly higher compression ratios. This dimensional change allows much longer lengths of flexible ducting to be packed into the same shipping container volume, directly increasing the quantity of ducting that can be transported per shipment and reducing storage and shipment costs
3Volume of moving object
If axial compression is applied to flexible ducting, then the ducting is compacted, but the insulating layer and vapor barrier can be damaged
Solution Approach 1:
The rigid structural support is positioned beforehand to surround and protect the vapor barrier and insulating layer during radial compression. This pre-positioned protective structure prevents damage to the delicate internal components while allowing aggressive compression to reduce volume, thus resolving the contradiction between volume reduction and preventing harmful damage
Data Source
AI summary
A system for packing and assembling a flexible duct that includes a sleeve. The sleeve includes a tubular vapor barrier and an insulating layer within the vapor barrier and includes a central cavity. Further, the sleeve is radially compressed and rolled along an axial direction. The system also includes an air core sized to fit within the central cavity of the insulating layer. The air core includes a sheet that blocks fluid flow therethrough and a structural support coiled within the sheet and the air core is flattenable and not within the rolled sleeve.