Radial Compression Packaging for Flexible Duct Storage and Shipping
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Solution Overview
Problem
The high cost of storing and shipping flexible ducting for HVAC systems is exacerbated by the limited axial compression, which can damage components and result in inefficient use of space, leading to increased storage and shipping costs.
Innovation Solution
Radial compression packaging of flexible ducts, where the sleeve is radially compressed and rolled, and the air core is flattened and packaged separately, allowing for more efficient use of space and reducing the risk of damage during transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If axial compression is used to reduce storage and shipping volume, then space utilization improves, but components may be damaged due to excessive compression
Solution Approach 1:
The patent transitions from axial compression (one-dimensional) to radial compression (another dimension). The flexible duct is compressed radially by rolling it onto a spool, which dramatically reduces the volume occupied by the duct while applying compression forces that do not damage the insulating layer or other components. This dimensional change allows for much higher compression ratios without compromising component integrity.
Solution Approach 2:
The patent changes the compression parameter from axial direction to radial direction. By compressing the duct radially rather than axially, the compression ratio can be increased from limited axial compression to extensive radial compression (rolling onto spool), achieving 20% to 100% more efficient space utilization while maintaining component integrity through controlled application of compression forces.
2Reliability
If axial compression is limited to prevent damage, then component integrity is maintained, but space utilization becomes inefficient
Solution Approach 1:
The patent resolves this contradiction by moving the compression action to the radial dimension. The duct is rolled onto a spool, which compactly stores long lengths of duct in a minimal volume while maintaining component integrity. This approach allows the duct to be compressed to a much smaller volume than axial compression permits, while the rolling process applies compression in a controlled manner that does not damage the insulating layer.
3Quantity of substance
If more flexible duct is packed in the same volume, then shipping costs decrease, but compression ratio increases and may damage the insulating layer
Solution Approach 1:
The patent enables packing 20% to 100% more flexible duct in the same volume by switching to radial compression. The duct is rolled onto a spool, which compactly stores long lengths in minimal space. The radial compression applied during rolling is distributed evenly and controlled, preventing damage to the insulating layer while achieving the high compression ratios needed to increase the quantity of duct that can be shipped.
Solution Approach 2:
The patent applies preliminary radial compression by rolling the duct onto a spool before shipping. This preliminary action compactly stores the duct in a space-efficient configuration while the controlled rolling process ensures the insulating layer is not damaged. The duct is then ready for shipping in a compact form that maximizes the quantity that can be transported.
Data Source
AI summary
A system for packing and assembling a flexible duct that includes a sleeve. The sleeve includes a tubular vapor barrier and an insulating layer within the vapor barrier and includes a central cavity. Further, the sleeve is radially compressed and rolled along an axial direction. The system also includes an air core sized to fit within the central cavity of the insulating layer. The air core includes a sheet that blocks fluid flow therethrough and a structural support coiled within the sheet and the air core is flattenable and not within the rolled sleeve.