Plenum Fan Interface with Bracket-Gasket Seal for Tool-Free Assembly
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Solution Overview
Problem
Existing environmental control systems, such as HVAC units, require complex and time-consuming assembly and maintenance processes due to the need for manual access to secure plenum fans to ductwork, increasing costs and operational complexity.
Innovation Solution
An improved interface between the fan and ductwork, featuring a first bracket coupled to the fan and a second bracket on the ductwork frame, with a sealing member like a gasket, fabric, or bellow to create a seal without mechanical securement, allowing for simplified assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mechanical securement methods (bolts, screws, rivets) are used to connect the fan to the duct, then the connection strength and reliability are improved, but the assembly complexity and maintenance difficulty increase due to the need to access fasteners and openings
Solution Approach 1:
The patent extracts the fastening function from the mechanical securement system and relocates it to a separate interface mechanism. The fan and duct are designed with complementary interface features (protrusions and recesses, or mating surfaces) that connect without requiring fasteners, thereby simplifying assembly while maintaining connection reliability through the dedicated interface design
Solution Approach 2:
The patent introduces an interface mechanism as an intermediary between the fan and duct. This interface includes sealing members, brackets, or coupling elements that mediate the connection, providing both mechanical attachment and sealing functions without requiring direct mechanical securement with fasteners, thus reducing assembly complexity
2Strength
If traditional mechanical securement methods are used to connect the fan to the duct, then the connection strength is improved, but the assembly time and maintenance cost increase
Solution Approach 1:
The patent segments the connection system into modular interface components that can be independently designed and assembled. The fan and duct each have standardized interface features that mate together, allowing for rapid assembly without the time-consuming process of installing and tightening multiple fasteners, while maintaining connection strength through the segmented interface design
Solution Approach 2:
The patent replaces the traditional mechanical fastening system with an alternative interface mechanism that achieves secure connection without bolts, screws, or rivets. This substitution uses features such as snap-fit connections, friction-fit interfaces, or interlocking geometries that provide sufficient connection strength while dramatically reducing assembly time
3Reliability
If the fan is directly secured to the duct with fasteners, then the sealing effect is improved, but the ease of assembly and maintenance deteriorates due to the need for mechanical securement
Solution Approach 1:
The patent introduces sealing members as intermediary elements between the fan and duct interfaces. These sealing members (such as gaskets, seals, or flexible barriers) are integrated into the interface mechanism, providing reliable sealing while allowing the fan and duct to be connected through simple interface features rather than complex mechanical securement, thereby improving ease of assembly
Solution Approach 2:
The patent merges the sealing function with the mechanical interface features. Instead of separate sealing components requiring additional installation steps, the sealing function is combined with the interface geometry itself or integrated into the same assembly operation, achieving both reliable sealing and ease of assembly through a unified interface design
Data Source
AI summary
Embodiments of the present disclosure are directed to an interface for a fan that includes a first bracket coupled to the fan, where the fan is configured to direct a flow of air through an opening of a duct, and the opening comprises a central axis extending therethrough, a second bracket coupled to a frame surrounding the opening of the duct, where the first bracket and the second bracket are configured to surround the opening of the duct, the second bracket is configured to support the first bracket, and the second bracket is partially radially within the first bracket relative to the central axis of the opening, and a gasket disposed between the first bracket and the second bracket, where the first bracket, the second bracket, and the gasket are configured to sealingly engage with one another without mechanical securement.