Self-Sealing Transition Module for Lower-Cost ERV Installation
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Solution Overview
Problem
The high shipping and installation costs associated with energy recovery ventilator units are due to their large packaging and the labor-intensive assembly process, which often requires cranes or helicopters for lifting and manual formation of sealing rings.
Innovation Solution
A separate transition module for energy recovery ventilator units, featuring a frame with through-hole openings and a self-sealing surface, allows for reduced panel sizes, easy mounting, and eliminates the need for manual sealing, thereby reducing shipping and installation costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If energy recovery ventilator units are manufactured as complete assemblies, then functional performance is ensured, but shipping and installation costs increase due to large packaging requirements and labor-intensive assembly processes
Solution Approach 1:
The energy recovery ventilator system is divided into separate modular components: the ERV unit itself and the transition module. The transition module is further segmented into a frame, self-sealing surface, and mounting mechanisms. This segmentation allows each component to be manufactured and shipped independently, reducing packaging size and simplifying installation while maintaining system functionality.
Solution Approach 2:
The transition module serves as an intermediary component between the ERV unit and the air handling unit or ductwork. It provides the necessary connection interface and sealing functionality, eliminating the need for complex on-site assembly and manual sealing operations while ensuring proper integration of the ERV system.
2Reliability
If traditional sealing methods are used during installation, then sealing performance is achieved, but labor costs and installation time increase due to manual formation of sealing rings
Solution Approach 1:
The transition module incorporates a self-sealing surface that automatically forms seals when the module is mounted to the air handling unit or ductwork. The self-sealing surface includes compliant sealing elements that conform to the mating surface, eliminating the need for manual sealing operations while ensuring reliable sealing performance. This self-service sealing mechanism significantly reduces installation time and labor costs.
3Reliability
If complete ERV units are shipped in large packaging, then all components are protected, but shipping costs and handling requirements increase
Solution Approach 1:
The system is segmented into the ERV unit and the transition module, which can be shipped separately. The transition module is designed as a compact, lightweight component that can be easily handled and transported. This segmentation reduces the overall shipping weight and allows for more efficient packaging and transportation logistics while ensuring both components arrive protected and intact.
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 transition module decreases shipping and installation expenses by enabling smaller unit sizes and eliminating the need for manual sealing, simplifying the installation process and reducing labor costs.
Implementation Method 1
a self-sealing surface on one of the major surfaces and surrounding the two through-hole openings
Data Source
AI summary
A transition module for an energy recovery ventilator unit. The module comprises a frame having two opposing major surfaces with two separate through-hole openings therein. The module also comprises a self-sealing surface on one of the major surfaces and surrounding the two through-hole openings. One of the through-hole openings is configured to separately overlap with return air openings or supply air openings located in a first target side of one an energy recovery ventilator unit or an air handling unit and in a second target side of the other one of the energy recovery ventilator unit or the air handling unit. The other of the through-hole openings is configured to separately overlap with the other of the return air openings or the supply air openings located in the first and second sides.