Nested-Duct Diffuser Assembly to Reduce HVAC Complexity and Size
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Solution Overview
Problem
Conventional HVAC diffusers have complex designs with obstructed airflow paths, leading to increased size, material usage, and assembly time, while compromising on airflow efficiency and performance.
Innovation Solution
A simplified diffuser assembly with a housing and internal return air duct that defines a direct, unobstructed return air path and a supply air path, reducing the number of parts and using materials like sheet metal or fiberglass, resulting in improved airflow efficiency and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional diffuser designs are used, then structural strength and durability are maintained, but device complexity and manufacturing cost increase
Solution Approach 1:
The diffuser is divided into two separate components: a housing component and a liner component. The housing provides structural support while the liner defines the airflow passages. This segmentation allows each component to be optimized for its specific function, reducing overall complexity while maintaining structural integrity.
Solution Approach 2:
The liner is positioned within the housing, with the housing forming an outer shell and the liner forming an inner structure. This nested arrangement allows the airflow-defining liner to be supported by the structurally-strong housing without requiring the housing itself to form complex airflow passages, thereby simplifying the overall design.
2Productivity
If conventional diffuser designs with obstructed airflow paths are used, then structural stability is maintained, but airflow efficiency deteriorates
Solution Approach 1:
The liner is extracted as a separate component that specifically defines the airflow passages, removing the complexity of forming obstructed paths from the housing. This allows the housing to maintain structural stability while the liner can be designed to provide unobstructed airflow paths for both supply and return air.
Solution Approach 2:
Instead of forming airflow passages by removing material from a solid housing, the design inverts the approach by having the liner form the passages within the housing cavity. This inversion simplifies the housing design to a simple shell while allowing complex, efficient airflow paths to be defined by the liner.
3Volume of moving object
If conventional diffuser designs are used, then adequate airflow capacity is achieved, but diffuser size increases
Solution Approach 1:
The design utilizes the three-dimensional space within the housing cavity more efficiently by having the liner extend along the longitudinal axis and define airflow passages in multiple directions. This dimensional optimization allows adequate airflow capacity to be achieved within a more compact overall size compared to conventional designs that require larger dimensions to accommodate obstructed airflow paths.
4Ease of manufacture
If conventional diffuser designs are used, then manufacturing robustness is maintained, but assembly time increases
Solution Approach 1:
By segmenting the diffuser into housing and liner components, each can be manufactured independently using robust, simple processes. The housing can be formed as a simple shell while the liner can be manufactured separately and then inserted into the housing, reducing assembly time compared to conventional designs that require forming complex integrated structures.
Solution Approach 2:
The nested arrangement of the liner within the housing allows for simple assembly where the liner is inserted into the pre-formed housing. This reduces assembly complexity and time while maintaining manufacturing robustness, as both components can be manufactured using standard, well-established processes for simple geometric forms.
Data Source
AI summary
A diffuser assembly includes a housing that defines an internal chamber having an open end, a return air outlet, and a supply air inlet; a cover sized to cover the open end, wherein the cover defines a return air inlet and a supply air outlet; and an internal return air duct longitudinally extending within the internal chamber and connecting the return air inlet and the return air outlet, wherein the internal return air duct includes an inner duct surface that defines a return air chamber within the internal return air duct and an outer duct surface that defines a supply air chamber between the housing and the outer duct surface, wherein the supply air chamber defines a supply air path between the supply air inlet and the supply air outlet.