Pre-insulated ductwork railing technology
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Solution Overview
Problem
Conventional HVAC ductwork faces issues with suboptimal thermal insulation, uniformity, air and water leakage, material exposure, durability, weight, cost, and installation difficulties, particularly with outdoor pre-insulated ducts requiring additional insulation and insecure mounting.
Innovation Solution
A pre-insulated HVAC duct with a multi-tube, multi-wall construction featuring nested composite tubes with foam and metal walls, providing exceptional thermal insulation, light weight, and a mounting rail system for secure installation, along with a connection mechanism using male and female detents for easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional HVAC ductwork is used, then installation is simpler, but thermal insulation properties are suboptimal and non-uniform
Solution Approach 1:
The patent employs a nested tube construction where an inner tube is placed inside an outer tube, creating multiple insulating chambers. This nested configuration provides enhanced and more uniform thermal insulation compared to conventional single-walled ducts, while the modular design maintains reasonable installation complexity.
Solution Approach 2:
The ductwork utilizes composite construction with multiple materials including inner and outer tubes, insulation materials filling the chambers between tubes, and various sealing components. This composite approach optimizes thermal insulation properties by combining materials with different thermal characteristics, addressing the contradiction between insulation performance and construction complexity.
2Reliability
If conventional ductwork is used, then manufacturing is simpler, but air and water leakage is more prevalent
Solution Approach 1:
The nested tube design creates multiple barriers against air and water leakage. The inner tube within the outer tube provides redundant sealing paths, and the insulation material filling the chamber between tubes acts as an additional barrier, significantly improving reliability against leakage compared to conventional single-walled ducts.
Solution Approach 2:
The ducts are pre-assembled with insulation material already positioned between the inner and outer tubes before installation. This preliminary action ensures proper insulation placement and sealing configuration, improving manufacturing efficiency while maintaining high reliability against air and water leakage.
3Strength
If conventional ductwork is used, then material cost is lower, but durability is reduced
Solution Approach 1:
The ductwork employs composite construction with multiple materials including metallic or plastic tubes, insulation materials, and sealing components. This composite structure enhances durability by combining materials with different strength and resistance properties, protecting against corrosion, physical damage, and environmental degradation while distributing material costs across multiple functional layers.
4Temperature
If conventional ductwork is used, then weight is higher, but insulation performance is suboptimal
Solution Approach 1:
The insulation material is strategically positioned in the chambers between the inner and outer tubes, providing targeted thermal insulation where most needed. This local quality approach optimizes insulation performance while minimizing unnecessary material usage and weight, as insulation is concentrated in the most effective locations rather than uniformly distributed.
5Reliability
If conventional ductwork is used, then installation is simpler, but mounting security is insufficient
Solution Approach 1:
The duct system is segmented into modular sections with standardized connection interfaces. This segmentation allows for secure mounting through repeated connection points along the duct length, improving mounting security while maintaining installation ease through modular assembly. The segmented design enables flexible positioning and secure attachment at multiple locations.
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 offers superior thermal insulation, durability, and ease of installation while reducing weight and cost, ensuring secure mounting and minimizing air and water leakage.
Implementation Method 1
a pre-insulated duct having a length and comprising a tube having a foam layer
Data Source
AI summary
The invention provides a pre-insulated duct having a length and comprising a tube having a foam layer. The pre-insulated duct has an interior face and an exterior face and a thickness defined as a distance between the interior face and the exterior face. The interior face of the pre-insulated duct bounds an airflow space. In the present group of embodiments, the pre-insulated duct has a mounting rail system extending along the length of the pre-insulated duct. The mounting rail system includes at least one mounting rail, and preferably a plurality of mounting rails, positioned on (e.g., positioned on an exterior of) the pre-insulated duct.