Portable Flexible Insulated Duct Production for Exact On-Site Lengths
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Solution Overview
Problem
Existing methods for manufacturing flexible insulated ducts result in large, bulky machines that produce ducts in fixed lengths, leading to waste and inefficiency as users must cut the ducts to desired lengths, creating unusable scrap portions.
Innovation Solution
A vehicle-transportable flexible insulated duct manufacturing machine that wraps a tubular core with insulation and an outer layer, overlapping the edges to form a seam, which is then bonded and cut to a discrete length, allowing for on-site production of flexible insulated ducts of desired length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large and bulky manufacturing machine is used to produce flexible insulated duct in predetermined fixed lengths, then the duct can be manufactured with consistent quality and insulation properties, but the machine size increases and requires compression packaging, leading to shipping costs and on-site cutting waste
Solution Approach 1:
The manufacturing process is segmented into modular components: a collapsible frame structure that can be assembled in sections, with each section performing a specific function (core formation, insulation application, outer layer wrapping). This allows the machine to be transported in compact parts while maintaining manufacturing precision when assembled.
Solution Approach 2:
The machine employs dynamic, collapsible framing structures that can be compressed for transport and expanded for operation. The frame members are designed to telescope or fold, transforming the machine from a bulky stationary configuration to a compact portable configuration, eliminating the need for large packaging while maintaining manufacturing capabilities.
2Ease of manufacture
If flexible insulated duct is produced in predetermined fixed lengths and then cut to desired lengths, then the manufacturing process is simplified, but unusable scrap portions are created leading to material waste
Solution Approach 1:
The machine incorporates a dynamically adjustable cutting mechanism that can be positioned at any location along the duct production line. This allows the duct to be cut to any desired length on-site without creating waste, as the cutting position can be precisely controlled to match the exact requirements of the installation.
Solution Approach 2:
The portable machine enables the end-user to manufacture duct to exact specifications on-site, eliminating the need for pre-cutting at the factory. The user can determine the precise length needed and cut only that amount, with no scrap material generated, while the machine provides all necessary manufacturing functions in a compact form.
3Adaptability or versatility
If flexible insulated duct is manufactured in a portable machine and transported to the usage location, then on-site production eliminates shipping costs and waste, but the machine must be transportable while maintaining manufacturing capabilities
Solution Approach 1:
The machine is divided into separate functional modules that can be independently assembled and disassembled. Each module contains specific components (motor assembly, insulation applicator, outer layer dispenser) that can be transported separately and quickly assembled at the job site, reducing transport complexity while maintaining full manufacturing capability.
Solution Approach 2:
The machine employs collapsible and telescopic structural elements that allow it to be compacted for transport in a vehicle and then expanded at the usage location. The frame members can fold or telescope, and the various components can be detached and reattached, enabling the machine to transition between portable and operational states without permanent structural compromise.
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 method eliminates the need for pre-cut ducts, reducing waste and shipping costs by enabling on-site manufacturing of flexible insulated ducts, improving energy efficiency and convenience for users.
Implementation Method 1
A source of heat directs heat at the longitudinally extending seam and bonds the overlapping longitudinal edges together
Data Source
AI summary
A method of manufacturing flexible insulated duct includes wrapping a substantially flexible tubular core with a layer of insulation. A substantially flexible outer layer is wrapped about the layer of insulation such that longitudinal edges of the outer layer circumferentially overlap to define a longitudinally extending seam. The overlapping longitudinal edges of longitudinally extending seam in the outer layer are bonded together, thereby forming the flexible insulated duct. The flexible insulated duct is then cut to a discrete length and installed at a job site.