Interlocking Polymeric Damper Blade Assembly for HVAC Air Sealing
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Solution Overview
Problem
Traditional metallic damper blades in HVAC systems are costly to manufacture and ineffectively block air flow when transitioned to closed positions, leading to air leaks.
Innovation Solution
Polymeric damper blades manufactured via extrusion, featuring interlocking components and integrated finger gaskets that form a fluid seal when closed, reducing manufacturing complexity and enhancing air-blocking ability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic damper blades are used, then structural strength is improved, but manufacturing cost increases and air sealing performance deteriorates
Solution Approach 1:
The damper blade is divided into multiple segments (first damper blade piece, second damper blade piece, etc.) that can be manufactured separately and then assembled together. This segmentation allows each piece to be produced more easily while maintaining the overall structural strength through the interlocking assembly of multiple components.
Solution Approach 2:
The patent employs composite construction by combining multiple damper blade pieces with interlocking features to form a complete damper blade assembly. This composite approach enables the use of more manufacturable materials and processes for each individual piece while achieving the required overall strength through the assembled structure.
2Strength
If metallic damper blades are used, then structural strength is improved, but air sealing performance worsens due to ineffective blocking in closed positions
Solution Approach 1:
The patent incorporates finger gaskets that function as flexible sealing elements between the damper blade pieces and against the damper housing. These flexible sealing components conform to surfaces and effectively block air leakage paths, significantly improving air sealing performance when the damper is in the closed position.
Solution Approach 2:
The segmented design of the damper blade with multiple pieces creates multiple sealing surfaces and contact points with the finger gaskets, enhancing the overall sealing effectiveness compared to a single-piece design. The segmentation allows for better distribution of sealing forces and more comprehensive coverage of potential leakage paths.
3Ease of manufacture
If polymeric damper blades with interlocking components are used, then manufacturing cost is reduced and air sealing is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into the damper blade assembly: the interlocking features of the blade pieces serve both structural assembly purposes and positioning functions for the finger gaskets. The finger gaskets themselves serve dual roles as sealing elements and as features that guide the closure action. This merging of functions reduces the need for separate components, thereby limiting the increase in device complexity.
Solution Approach 2:
The interlocking features are designed to enable self-alignment and self-assembly of the damper blade pieces during installation or replacement. The finger gaskets are integrated into the blade structure and automatically position themselves to provide sealing when the damper closes, eliminating the need for separate adjustment or installation procedures for sealing components.
Data Source
AI summary
A heating, ventilation, and/or air conditioning (HVAC) system includes a damper assembly configured to regulate airflow and having a frame. The HVAC system includes a first damper blade piece having a first airfoil surface and a second damper blade piece having a second airfoil surface. The first damper blade piece and the second damper blade piece are configured to couple with the frame, and are configured to interlock with one another to form a damper blade having an airfoil shape.