Method for producing a flexible ventilation duct
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Solution Overview
Problem
Existing methods for manufacturing flexible ventilation ducts are complex and not suited for industrial-scale production, particularly for factories and public spaces, as they require multiple components and assembly processes that are time-consuming and difficult to implement.
Innovation Solution
A continuous manufacturing process where two overlapping edges of a textile strip are sewn together to form a helicoid tubular wall, allowing for the production of flexible ventilation ducts with a marking and accessories for identification and suspension, using a machine with a sewing head and translational movement to wind the fabric around a mandrel, enabling precise length control and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple fabric strips are joined using Velcro strips or zippers to create long ventilation ducts, then custom-length ducts can be achieved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The fabric width is divided into multiple sections that can be independently handled and then joined together. Each section can be processed separately through the welding and forming operations, then assembled into the final duct structure, enabling flexible length customization without requiring complex multi-component assembly processes.
Solution Approach 2:
Multiple fabric sections are joined by welding their overlapping edges to form a continuous tubular structure. This merging approach eliminates the need for separate joining components like Velcro or zippers, simplifying the overall manufacturing process while maintaining the ability to create ducts of various lengths.
2Adaptability or versatility
If multiple fabric strips are joined using Velcro strips or zippers, then long ventilation ducts can be manufactured, but production efficiency decreases due to repeated assembly operations
Solution Approach 1:
The welding process operates continuously as the fabric moves through the system, with the welding head moving along the fabric width to join overlapping edges in a single uninterrupted operation. This continuous welding approach eliminates repeated assembly stops and starts, significantly improving production speed while maintaining the ability to manufacture ducts of various lengths.
3Productivity
If a continuous manufacturing process is used with fabric wound helically around a mandrel, then production efficiency increases, but precise control of the tubular wall formation becomes more difficult
Solution Approach 1:
The system incorporates sensors and control mechanisms that monitor the fabric winding process, overlap consistency, and welding quality in real-time. This feedback allows for automatic adjustments to maintain precise tubular wall formation during continuous helical winding, ensuring manufacturing accuracy is preserved despite the high-speed continuous production process.
Solution Approach 2:
The system dynamically adjusts critical parameters such as winding tension, overlap width, and welding speed to maintain precise tubular wall formation. By controlling these parameters during the continuous helical winding process, the system achieves both high productivity and manufacturing precision in the formed duct structure.
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 method allows for the efficient and precise production of flexible ventilation ducts that can diffuse air, with marked identification and accessory integration, suitable for controlled ventilation systems, enhancing air transport and distribution in industrial and commercial settings.
Implementation Method 1
The width forms a helix that constitutes the tubular wall of the flexible ventilation duct
Implementation Method 2
The process involves sewing the two overlapping edges together
Data Source
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AI summary
The present invention relates to a method for manufacturing a flexible ventilation duct (Gv) sized for use in the field of industrial ventilation, the method employing a cylindrical tubular mandrel (M).According to the invention, the method consists of: - winding a width (T) made of textile on one turn around the mandrel (M) with a non-zero angle of incidence "a" considering the direction of advancement of the width (L) with respect to a plane perpendicular to the axis of the mandrel, so that one edge (B2) of the width L is covered by superposition by the other edge (B1) of the part of the width being approached by the mandrel (M) - rotating said width around the mandrel (M), - continuously joining the two superimposed edges (B1) by means of a sewing head (Tc) or a welding head or a gluing head, equipped with a means of translational movement (Mt) of the fabric, characterized in that it consists of using the means of translational movement (Mt) of the fabric to continuously wind the width (L) around the mandrel (M). This method of manufacturing a flexible ventilation duct allows it to be made continuously.The width forms a helicoid which constitutes the tubular wall of the flexible ventilation duct.