Segmented Flange Design for 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 aligned to guide self-tapping screws, reducing the need for high forces and torques, and minimizing material deformation by positioning fasteners through pre-defined areas, ensuring a secure and efficient assembly process.
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 attachment is achieved, but excessive pressure and torque are required causing material deformation and assembler injury
Solution Approach 1:
The flange is divided into multiple wall members (first wall member, second wall member, third wall member) that can be positioned on different sides of the duct member. This segmentation allows fasteners to be inserted from accessible sides without passing through all layers, reducing insertion force requirements and preventing material deformation while maintaining secure attachment.
2Strength
If fasteners are passed through multiple layers of sheet metal, then flange attachment is achieved, but assembly time increases due to high force requirements
Solution Approach 1:
By segmenting the flange into multiple wall members positioned on different sides of the duct, the fastening process can be performed from accessible sides without requiring fasteners to pass through all material layers. This reduces assembly time by eliminating the need for high-force insertion through multiple layers while maintaining secure attachment.
3Strength
If fasteners are passed through multiple layers of sheet metal, then flange attachment is achieved, but the fit becomes loose due to material deformation
Solution Approach 1:
The segmented flange structure with wall members on different sides of the duct prevents material deformation by avoiding the need to pass fasteners through all material layers. This maintains the precise fit between flange and duct components while achieving secure attachment through strategically positioned fasteners.
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 flange design facilitates faster, more efficient, and secure assembly of duct members with reduced material deformation and improved fit, minimizing assembler effort and preventing injuries, while maintaining material strength and reducing assembly errors.
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 be 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.