Method for producing a ductwork damper, ductwork damper, and ductwork damper unit incorporating same
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Solution Overview
Problem
Conventional HVAC system dampers are complex and costly to produce due to their numerous components, and they often suffer from air leakage issues.
Innovation Solution
A simplified damper design featuring a sheet metal preform with diametrically opposed arms and an indentation for rigidity, combined with bushings made of soft pliable materials like silicone rubber for secure and airtight pivoting, reducing component count and enhancing airflow control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional dampers use multiple bearing elements and aligned holes for pivoting, then the damper can rotate smoothly, but the number of components increases and manufacturing complexity increases
Solution Approach 1:
The patent merges the pivot arm and bearing element into a single integrated component. The pivot arm includes an integrated bearing surface that directly contacts the duct wall, eliminating the need for separate bearing elements and alignment holes. This consolidation reduces the number of components while maintaining smooth rotation capability through the integrated bearing surface.
2Strength
If conventional dampers use multiple components for structural integrity, then the damper maintains rigidity, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple structural elements into a single stamped metal body. The body includes integrated features such as the pivot arm, bearing surface, and structural ribs all formed in one piece through stamping operations. This eliminates the need for separate components and assembly operations, reducing manufacturing cost while maintaining structural rigidity through the integrated design.
3Ease of manufacture
If conventional dampers use standard mounting methods, then installation is straightforward, but air leakage occurs at pivot points
Solution Approach 1:
The patent uses a flexible gasket or seal element that conforms to the bearing surface and duct wall interface. This flexible sealing element prevents air leakage at the pivot point while allowing the damper to rotate freely. The seal maintains contact pressure through elasticity, ensuring an airtight seal during operation.
4Strength
If conventional dampers use extensive material for component fabrication, then component strength is sufficient, but material efficiency decreases
Solution Approach 1:
The patent optimizes material distribution by segmenting the metal body into functional zones with appropriate thickness and reinforcement. Critical areas such as the pivot arm and bearing surface receive localized reinforcement, while non-critical areas use minimal material. This segmented approach maintains component strength where needed while reducing overall material consumption.
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
The solution significantly reduces manufacturing costs and eliminates air leakage by using fewer components and a unique bushing design that provides a tight seal and smooth rotation, improving the efficiency of HVAC systems.
Implementation Method 1
A bushing for pivotally mounting a damper to a section of ductwork... includes a member made of a soft pliable material... providing a tight seal and smooth rotation
Implementation Method 2
The tapered opening in the bushing is such that one side is dimensioned to snugly receive the pivot arm, and the opposite side is of slightly less dimension than the pivot arm. Upon assembly, when the pivot arm is inserted into the opening... a small outward force will be applied by the pivot arm to the body of the bushing member... This force will cause the bushing material to expand radially outwardly thus increasing the already tight fit
Data Source
AI summary
A method for producing an air duct damper includes the steps of punching from sheet metal stock a damper preform having a body and two diametrically opposed arms extending from opposite sides of the body; and forming an indentation in the damper preform extending between and up to respective ends of the two arms.