Saddle Tap Connection for Corrosive Ductwork

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Solution Overview

Problem

The existing methods for installing ductwork connections in corrosive vapor exhaust systems are labor-intensive, time-consuming, and require skilled labor, often compromising the integrity of the duct system due to the need for extensive sanding, multiple sealants, and complex lay-up processes, especially when flexibility in duct layout is required.

Innovation Solution

The use of an internal slip collar with a slip collar flange and an external saddle tap, which allows for secure and leak-proof connections without screws or bolts, and eliminates the need for extensive sanding and lay-up processes, using adhesives to create a self-aligning and double-sealed assembly that can be installed efficiently and flexibly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional on-site installation methods are used with sanding and multiple sealants, then leak-proof connections can be achieved, but installation time and labor costs increase significantly

Engineering Contradiction:

Improveleak-proof connectionVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The collar is pre-formed with integrated flanges and bonding surfaces during manufacturing, eliminating the need for on-site sanding and preparation. The bonding surfaces are pre-treated to ensure optimal adhesive bonding, allowing the installation to proceed directly to sealing and assembly without time-consuming surface preparation steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The collar integrates multiple functions into a single component: the tubular body provides structural support and alignment, while the first and second flanges provide bonding surfaces for attachment to the duct and tap respectively. This consolidation eliminates the need for separate flanges, gaskets, and multiple sealant applications, reducing both installation time and the number of components required.

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If extensive sanding and lay-up processes are performed, then joint strength and seal integrity are improved, but the process becomes more complex and requires skilled labor

Engineering Contradiction:

Improvejoint strengthVSAvoidinstallation process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention extracts and eliminates the complex sanding and lay-up processes from the installation procedure. By designing the collar with pre-formed bonding surfaces and integrated flanges, the method removes the need for skilled labor-intensive operations while maintaining joint strength through simplified adhesive bonding between the collar, duct, and tap.

Inventive Principle:

Principle #2Taking out (Extraction)

3Adaptability or versatility

If flexible duct layout adjustments are needed at the job site, then adaptability is improved, but the risk of compromising system integrity increases

Engineering Contradiction:

Improveduct layout flexibilityVSAvoidsystem integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The collar acts as an intermediary component between the duct and the tap, providing a standardized interface that maintains system integrity while enabling flexible positioning. The collar's bonding surfaces and flanges ensure reliable attachment regardless of the tap's location on the duct, allowing layout adjustments without compromising the leak-proof seal or structural strength.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The connection system is segmented into distinct components: the duct, the collar, and the tap. This segmentation allows the collar to be independently positioned and attached to the duct at various locations, providing layout flexibility. Each component maintains its structural integrity, and the standardized bonding interfaces ensure reliable connections regardless of installation location.

Inventive Principle:

Principle #1Segmentation

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 significantly reduces installation time and costs by providing a strong, leak-proof connection that maintains system integrity even in harsh chemical environments, allowing for flexible duct layout adjustments without compromising the seal's integrity.

Implementation Method 1

using adhesives to create a self-aligning and double-sealed assembly

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS8540287B2Saddle tap connection and installation device

Publication Date: 2013.09.24 ATS PRODS

AI summary

Internal collars and external saddle taps can be used to install taps on a main duct in a manner that maintains duct section joint integrity. A saddle tap assembly may include an external slip tap, internal tap collar, a duct section, and adhesive. The external slip tap and the internal tap collar may each have a flange. The flanges may be curved. The flange of the internal collar may have a sheared portion permitting the flange of the internal collar to pass through an opening in a section of duct. The duct may have an opening with one or more notches. A method of installation can be more efficient and more cost-effective than prior solutions. An installation tool can be used for installing saddle tap assemblies while an adhesive cures.