Modular Sheet-Metal Duct Assembly for Low-Volume Shipping
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Solution Overview
Problem
The existing methods for fabricating and assembling ducting systems are costly due to expensive handling and forming processes in workshops, high storage and shipping costs, and complex on-site handling, especially with large duct cross-sections.
Innovation Solution
A tubular duct member is created by joining circumferential sheet metal panels with cooperating folded sheet metal catches, where the catches engage to retain the edges together, and a resilient material is used to maintain the engagement and provide a thermal insulating layer, allowing for easy assembly and reduced material and labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ducting is fabricated in a workshop using machines such as guillotines, press brakes and seamers, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The ducting system is divided into individual panels with integrated catches, allowing each panel to be manufactured separately using simple equipment and then assembled on-site. This segmentation eliminates the need for complex workshop machinery while maintaining manufacturing precision through standardized panel designs.
Solution Approach 2:
The catches are pre-formed as integral parts of each panel during the panel manufacturing process, rather than being added separately during assembly. This preliminary action simplifies the overall manufacturing process by combining multiple operations into a single panel fabrication step.
2Quantity of substance
If large duct cross sections are used, then air and gas distribution capacity is improved, but storage and shipping costs increase due to significant volumes
Solution Approach 1:
Large ducting systems are divided into multiple smaller panels that can be stored and shipped in compact configurations. The panels are assembled on-site to form the required large cross-section, reducing storage volume while maintaining the necessary air distribution capacity.
Solution Approach 2:
The panels are designed to be stored in a flat, two-dimensional configuration and then assembled into a three-dimensional duct structure at the installation site. This dimensional transformation significantly reduces storage and shipping volumes while preserving the final duct's air distribution capacity.
3Strength
If traditional workshop fabrication and shipping methods are used, then ducting structural integrity is maintained, but handling and shipping costs increase
Solution Approach 1:
The ducting system is segmented into manageable panels that are easier to handle and transport individually. Each panel maintains sufficient structural integrity for its size, and the modular design allows for simplified on-site handling and assembly compared to moving large, monolithic duct sections.
Solution Approach 2:
The panel design incorporates flexible yet strong materials and thin-walled constructions that maintain structural integrity while being lightweight and easy to handle. The catches provide reinforcement at critical joints without adding significant weight or complexity.
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 solution reduces production and shipping costs, facilitates easier handling and assembly, and provides a durable, airtight conduit with improved fire resistance and reduced bacterial and rodent harborage, making it suitable for applications in heating, ventilation, and air-conditioning systems.
Implementation Method 1
at least one of the catches includes a body of resilient material compressed between the catches and biasing the catches apart to maintain the detent surfaces bearing against one another
Implementation Method 2
the resilient material is used to maintain the engagement and provide a thermal insulating layer
Data Source
AI summary
A tubular duct member comprises a plurality of sheet metal panels 10, 12 joined along adjacent longitudinal edges by cooperating folded sheet metal catches 14, 16, the catches being pushed together such that respective detent surfaces 28, 30 on each catch engage behind one another to retain the edges of the sheets together. One of the catches 14 includes a body 36 of resilient material compressed between the catches and biasing the catches apart to maintain the detent surfaces 28, 30 bearing against one another.