Self-Locking Sheet Metal Duct Seam Sealing With Foam Insert
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing self-locking circular ducts leak due to the incompatibility of liquid sealants with manufacturing machines, leading to inefficiencies and additional cleaning requirements, and there is no known circular duct work sold with sealant already applied, necessitating additional materials and labor for sealing.
Innovation Solution
A sheet metal duct with a built-in interlocking mechanism and foam sealant, where the sealant is inserted into the mechanism during manufacturing, allowing for a sealed system without requiring additional sealing by the installer, using a forming machine to create the snap lock mechanism and inserting the sealant between specific rolls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid sealant is used with self-locking circular ducts, then sealing is achieved, but the sealant flows onto forming rolls and causes manufacturing issues
Solution Approach 1:
The patent changes the physical state and consistency of the sealant from liquid to foam form. This parameter change allows the sealant to remain contained within the duct seam during manufacturing without flowing onto forming rolls, while still providing effective sealing when the duct is assembled.
Solution Approach 2:
The patent utilizes the phase transition properties of foam sealant, which expands from a compact foam form to fill the seam space when activated. This phase transition enables the sealant to provide comprehensive sealing coverage without requiring liquid application methods that are incompatible with self-locking duct manufacturing.
2Reliability
If liquid sealant is applied to circular ducts shipped in bundles, then sealing occurs, but excess sealant adheres to duct surfaces and creates cleaning requirements
Solution Approach 1:
The patent changes the sealant from liquid to foam form, which has different flow and adhesion characteristics. The foam structure contains the sealant within the seam area, preventing it from adhering to the exterior surfaces of ducts in bundles, thereby eliminating cleaning requirements while maintaining sealing effectiveness.
3Ease of operation
If liquid sealant is used and self-locking mechanism is disengaged for cutting, then cutting is possible, but sealant integrity is compromised and sealing fails
Solution Approach 1:
The patent changes the sealant to foam form, which has cohesive properties that maintain seal integrity even when the self-locking mechanism is disengaged for cutting operations. The foam structure remains intact and can be reactivated when the duct is reassembled, unlike liquid sealant which loses integrity upon disengagement.
4Reliability
If liquid sealant is applied, then sealing is achieved, but VOC emissions and dust collection occur
Solution Approach 1:
The patent changes the sealant from liquid to foam form, which has reduced volatility and different surface properties. The foam structure minimizes VOC emissions compared to liquid sealants and prevents dust collection by eliminating the liquid surface that would otherwise attract and hold particulate matter.
Data Source
AI summary
A circular sheet metal duct having a sealant applied across the longitudinal seam. The sealant will improve the efficiency and will reduce or eliminate air leakage from the longitudinal seam. The sealant is applied during the manufacturing processes so that an installer does not have to seal the duct work. The method of manufacturing the sealant is provided.