Lance and Slit Seamed Blower Housing Assembly

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Solution Overview

Problem

Existing methods for manufacturing blower housing assemblies in HVAC systems are labor-intensive, pose health and safety risks, and are not adaptable to various sizes, styles, and sheet metal thicknesses, often resulting in inferior seams and air leakage.

Innovation Solution

A continuous lance and slit rolled seam method that simultaneously locks and seams blower housing panels and a wrapper together using adjustable rollers and fixtures, allowing for quick, safe, and secure assembly of diverse housing configurations from various sheet metal thicknesses and materials, without the need for welding or secondary operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is used to join panels and wrapper, then the seam strength is improved, but health and safety risks increase and labor time increases

Engineering Contradiction:

Improveseam strengthVSAvoidhealth and safety risks

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the thermal welding process with a mechanical rolling and lancing system. Rollers with lancing elements mechanically interlock the panels and wrapper through a rolling action, eliminating the need for welding operations and associated safety hazards while maintaining seam integrity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts the harmful welding process from the assembly operation and replaces it with a purely mechanical joining method. The welding step is completely removed from the process flow, eliminating safety risks while achieving the same joining function through mechanical means

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If welding or discrete stakes are used for seaming, then attachment is achieved, but the process becomes labor-intensive and time-consuming

Engineering Contradiction:

Improveattachment securityVSAvoidassembly speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent implements a continuous rolling operation where the housing sides and wrapper are fed continuously through the lancing and rolling mechanism. This eliminates the intermittent nature of welding or discrete staking, allowing for uninterrupted assembly and significantly improved production speed while maintaining secure attachment

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent combines multiple functions into a single integrated rolling operation. The lancing, interlocking, and seaming actions are merged into one continuous mechanical process performed by the rolling mechanism, eliminating the need for separate operations and reducing labor requirements

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If dedicated equipment is used for specific housing types, then manufacturing precision is improved, but adaptability to different sizes and thicknesses decreases

Engineering Contradiction:

Improveseam qualityVSAvoidhousing type flexibility

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent employs adjustable and reconfigurable tooling components that can be dynamically adjusted to accommodate different housing sizes, styles, and sheet metal thicknesses. The rolling mechanism and lancing elements can be repositioned and reconfigured without requiring dedicated equipment for each housing type, maintaining precision while enabling versatility

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent designs a universal assembly system that can handle multiple housing configurations through adjustable fixtures and reconfigurable rolling tools. A single piece of equipment performs the seaming function across various housing types, eliminating the need for dedicated equipment while maintaining consistent seam quality through proper adjustment

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If flanging and spot welding is used, then secure attachment is achieved, but the process prohibits pre-coating of sheet metal

Engineering Contradiction:

Improveattachment securityVSAvoidcoating applicability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent performs the seaming operation after the sheet metal has been pre-coated with non-conductive coatings. The mechanical rolling and lancing process is designed to work with coated materials, allowing the coating to be applied in advance without interfering with the attachment process, thereby enabling pre-coating while maintaining secure attachment

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS8756809B1Lance and slit seamed housing and method of manufacture

Publication Date: 2014.06.24 CUSTOM ROLLFORM PRODS

AI summary

A lanced and/or slit seamed housing and method of manufacture having a peripheral rolled and lanced or punched seam between a wrapper and the housing panels. The method of manufacture utilizes similar or dissimilar sheet materials in a variety of material thicknesses and with or without coatings applied prior to formation whereby a housing is formed quickly and safely. The rolling and lancing method manufactures a blower housing with an assured and positive sealed seam between the panels and wrapper of the housing. The lances or slits maintain the integrity of the seam and prevent slippage between the wrapper and panels.