Injection-Molded HVAC Diffuser Assembly with Integral Stem Fastening
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Solution Overview
Problem
Existing HVAC system diffusers made from heavy metals are prone to corrosion, rust, and damage, and those made from thermoformed plastic often use unreliable attachment techniques, leading to structural issues and undesirable characteristics.
Innovation Solution
An air diffuser made entirely from injection-molded plastic with integrally molded stems that secure the diffuser plates to a base platform, providing a durable and secure assembly similar to metal diffusers, using metal screws for attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal materials are used to form diffusers, then structural strength and durability are improved, but corrosion and rust occur leading to staining and damage
Solution Approach 1:
The patent changes the material parameter from metal to plastic, fundamentally altering the chemical properties to eliminate corrosion and rust while maintaining structural strength through appropriate plastic material selection and design
Solution Approach 2:
The patent uses plastic as a composite material alternative to metal, providing comparable structural properties without the harmful corrosion characteristics of metal materials
2Weight of moving object
If thermoformed plastic is used to form diffusers, then weight and cost are reduced, but attachment techniques become substandard leading to structural instability
Solution Approach 1:
The patent merges the diffuser components into a single integrally molded plastic structure, eliminating the need for separate attachment techniques and clips, thereby ensuring structural reliability while maintaining the weight advantages of plastic
Solution Approach 2:
The patent segments the diffuser into functional components (body, louvers, mounting features) that are all formed in one integral molding process, allowing each component to be optimized while maintaining overall structural integrity
3Duration of action of stationary object
If metal diffusers are used, then durability is improved, but they are susceptible to damage during construction as louvers are bent or dented
Solution Approach 1:
The patent changes the material parameter from metal to plastic, which fundamentally alters the mechanical properties to provide flexibility and resistance to permanent deformation during construction while maintaining long-term durability
4Object-affected harmful factors
If integrally molded plastic diffusers are used, then corrosion resistance and assembly ease are improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple manufacturing operations into a single integral molding process, creating a complex three-dimensional structure with integrated features (louvers, mounting tabs, recesses) in one step, thereby simplifying the overall manufacturing process while ensuring corrosion resistance
Data Source
AI summary
An air diffuser for use at a ventilation outlet of an HVAC system. The air diffuser comprises a base platform having an opening plenum formed from injection-molded plastic, the base platform including a collar for attachment to the outlet, the plenum defined by a perimeter rim, the edges of the rim lying substantially within a first common plane, at least one first diffuser plate positioned over the plenum, the first diffuser plate formed from injection-molded plastic and having edges lying substantially within a second common plane, and a plurality of stems integrally molded with one or more of the first diffuser plate and the base, the stems configured to secure the first diffuser plate to the base platform, each of the stems having a first end sized to fit within a complimentary female receptacle formed in one of the first diffuser plate and the base platform, the stems being formed via injection molding with one of the first diffuser plate and the base platform.