Duct panel

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Solution Overview

Problem

Conventional air duct installation is labor-intensive, prone to varying quality, and poses safety risks due to manual handling at elevated heights, with bulky and difficult-to-transport components that compromise insulation performance and lead to material wastage.

Innovation Solution

A duct panel with a laminate structure featuring an insulation layer between support layers, an end cap, and a metal mounting flange, where the end cap is made of plastic and the mounting flange is made of metal, forming a unitary construction, allowing for easier assembly and reduced material waste, with snap-lock mechanisms for efficient panel connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If air ducts are fabricated off-site in a workshop, then installation quality and safety are improved, but transportation difficulty and storage requirements increase due to bulky components

Engineering Contradiction:

Improveinstallation qualityVSAvoidtransportation difficulty

Core Design Contradiction:

Manufacturing precisionVSLength of moving object

Solution Approach 1:

The duct system is divided into modular panels that can be fabricated off-site with precise insulation and assembly, then transported as compact units to the installation site. Each panel is a self-contained module with standardized dimensions and connection features, enabling quality control in a workshop environment while reducing transportation burden compared to full-length ducts.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulation layer is integrated within the panel structure itself, with the insulation material nested between the inner and outer metal sheets. This nested configuration allows the insulation to be protected and compact during transportation, eliminating the need for separate insulation handling and reducing the overall footprint of transportable components.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If air ducts are installed manually at elevated heights, then flexibility in installation is maintained, but worker safety deteriorates and productivity decreases

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidinstallation productivity

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The duct panels are pre-assembled with mounting flanges, end caps, and connection mechanisms fabricated and prepared in advance at the workshop. This preliminary action allows complex assembly operations to be performed on the ground under controlled conditions, then the complete panels are lifted into position, eliminating the need for manual assembly at elevated heights and significantly improving productivity.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If conventional manual installation methods are used, then on-site adjustment flexibility is maintained, but material wastage increases and insulation performance is compromised

Engineering Contradiction:

Improveon-site adjustment flexibilityVSAvoidmaterial wastage

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The panel dimensions, insulation thickness, and material specifications are optimized during the design and fabrication phase to match the specific building requirements. By determining these parameters in advance, the panels are precisely sized to fit the intended applications, minimizing off-cuts and material wastage while ensuring adequate insulation performance without over-engineering.

Inventive Principle:

Principle #35Parameter changes

4Strength

If insulation layer is applied separately after duct fabrication, then duct structural integrity is maintained, but insulation performance deteriorates and additional labor is required

Engineering Contradiction:

Improveduct structural integrityVSAvoidinsulation performance

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The insulation layer is merged with the duct structure by sandwiching it between the inner and outer metal sheets during panel fabrication. This integrated construction ensures the insulation remains permanently protected and positioned, eliminating gaps and thermal bridges that would occur with separate application. The structural integrity of the duct is maintained through the layered composite construction, while insulation performance is enhanced by the continuous, protected insulation layer.

Inventive Principle:

Principle #5Merging (Combining)

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 enhances insulation efficiency, reduces on-site labor and material waste, improves safety by allowing off-site manufacturing and compact transportation, and increases productivity while maintaining structural integrity and thermal resistance.

Implementation Method 1

a laminate structure having an insulation layer disposed between a first support layer and a second support layer

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11549719B2Duct panel

Publication Date: 2023.01.10 INSTAD PRE FAB PTE LTD

AI summary

A duct panel, a method of manufacturing a duct panel, a duct section and a method of installing a duct are disclosed. The duct panel includes a laminate structure having an insulation layer disposed between a first support layer and a second support layer, the laminate structure having an end width; and an end cap attached to the end width and configured to be coupled to a mounting flange, wherein the mounting flange is configured to mount the duct panel. The end cap and the mounting flange comprise different materials.