Pre-Positioned Flange Fasteners for Easier Duct Assembly
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Solution Overview
Problem
Existing ventilation duct interconnection methods are inefficient due to high pressure and torque requirements, material deformation, and loose fits, caused by passing fasteners through multiple layers of sheet metal, leading to increased assembly costs and potential assembler injury.
Innovation Solution
A flange design with pre-fabricated fastener entry areas and indicators that align to guide self-tapping screws for secure attachment to duct members, reducing the need for excessive force and torque, and preventing material deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fasteners are passed through multiple layers of sheet metal to secure flanges to duct members, then the flange connection is achieved, but high pressure and torque requirements increase assembly difficulty and risk of assembler injury
Solution Approach 1:
The patent pre-positions fasteners in recesses within the flange structure before assembly, so that during installation the fasteners are already in place and only need to be driven a short distance through pre-punched holes in the duct member, rather than passing them through multiple layers of sheet metal during assembly
2Strength
If fasteners are passed through multiple layers of sheet metal, then the flange is secured to the duct member, but material deformation occurs leading to loose fit
Solution Approach 1:
The flange is pre-assembled with fasteners in recesses and pre-punched holes are created in the duct member before final attachment, ensuring proper alignment and preventing material deformation that would occur if fasteners were forced through multiple layers during assembly
Solution Approach 2:
The flange structure is divided into wall members with recesses that contain fasteners, separating the fastening function from the structural function, allowing the fasteners to engage only the duct member thickness rather than passing through multiple flange layers
3Reliability
If additional components are used to secure flanges to duct members, then the connection reliability is improved, but the interconnection cost increases
Solution Approach 1:
The flange structure integrates recesses and pre-positioned fasteners as part of the flange itself, combining the fastening mechanism with the flange structure rather than using separate additional components, thereby maintaining reliability while reducing complexity and cost
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
Facilitates efficient and secure assembly of duct components with reduced assembly time and material deformation, ensuring a tight fit and minimizing assembler risk.
Implementation Method 1
each of the plurality of first fastener indicators being sized to guide and each corresponding fastener entry areas being sized to receive a self-tapping screw fastener there through to fasten the wall members to the end portion of the duct member
Data Source
AI summary
A flange to he assembled to an end portion of a duct member includes a plurality of pre-fabricated fastener entry areas disposed in an inner wall member, and a plurality of first fastener indicators disposed on an outer wall member, wherein the pre-fabricated fastener entry areas are substantially aligned with the first fastener indicators, each of the plurality of first fastener indicators being sized to guide and each corresponding fastener entry areas being sized to receive a self-tapping screw fastener there through to fasten the wall members to the end portion of the duct member. The fastener entry areas and correspondingly aligned fastener indicators, respectively, may be spaced apart such that the fasteners can be inserted at regular intervals along the length of the flange and the length of the end of the duct member.