Semi-Rigid Flexible Duct With Smooth Inner Sleeve for Lint Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing semi-rigid flexible ducts lack structural integrity, leading to sagging and lint accumulation, which poses a fire hazard, and are often heavy, expensive, and inefficient to install, with manufacturing challenges due to material tearing during wrapping processes.
Innovation Solution
A semi-rigid, multi-purpose flexible duct constructed with a pair of coaxial aluminum sleeves and a resilient helical element, allowing for axial extension and compression, featuring a smooth inner surface to reduce friction and lint accumulation, and manufactured using a method that avoids material tearing by using thin aluminum ribbons and a fire-retardant adhesive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If vinyl-covered ducts are used for dryer exhaust, then flexibility is improved, but fire resistance deteriorates and structural integrity is lost
Solution Approach 1:
The duct combines aluminum foil layers with polyester fiberfill insulation and a vinyl outer layer to create a composite structure that maintains flexibility while achieving fire resistance through the aluminum and polyester components
Solution Approach 2:
The duct uses thin aluminum foil layers and polyester fiberfill to create a flexible yet structurally sound construction that resists sagging and maintains integrity without being overly rigid
2Reliability
If corrugated aluminum ducts are used for ventilation, then structural integrity is improved, but internal ridges cause friction and lint accumulation
Solution Approach 1:
The smooth aluminum foil inner layer replaces traditional corrugated aluminum, eliminating internal ridges and reducing lint accumulation while maintaining structural integrity through the flexible membrane structure supported by the polyester fiberfill
Solution Approach 2:
The combination of smooth aluminum foil with polyester fiberfill creates a composite structure that provides rigidity without internal corrugations, preventing lint buildup while maintaining structural soundness
3Strength
If solid aluminum tube ducts are used, then rigidity is improved, but weight and cost increase
Solution Approach 1:
The duct uses thin aluminum foil layers combined with polyester fiberfill to achieve the necessary rigidity and structural support without the weight of solid aluminum tubing
Solution Approach 2:
The composite construction of aluminum foil and polyester fiberfill provides structural rigidity comparable to solid aluminum while significantly reducing weight and material cost
4Weight of moving object
If thin aluminum ribbons are used in manufacturing, then material cost and weight are reduced, but material tearing during wrapping occurs
Solution Approach 1:
The polyester fiberfill is placed between the aluminum foil layers during manufacturing to act as a cushioning layer that prevents the thin aluminum ribbons from tearing during the wrapping process, enabling successful fabrication of lightweight ducts
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 duct maintains rigidity and structural integrity, reduces fire hazards by minimizing lint accumulation, and is lighter, less expensive, and easier to install, while the manufacturing process ensures durability and efficiency.
Implementation Method 1
a resilient helical element disposed between them, wherein the helical element imparts helical corrugations to the inner sleeve and the outer sleeve, such that the duct is axially extendible between a compacted configuration suitable for storage and for shipping and an extended configuration
Implementation Method 2
manufactured using a method that avoids material tearing by using thin aluminum ribbons and a fire-retardant adhesive
Data Source
AI summary
A semi-rigid, flexible duct including a pair of coaxial sleeves, namely an inner sleeve and an outer sleeve disposed parallel to and about the inner sleeve and a resilient wound element disposed between the sleeves. Each of the inner sleeve and the outer sleeve constitutes an aluminum foil ribbon. The wound element imparts corrugations to the two sleeves, such that the duct is extendible between a compacted configuration suitable for storage and for shipping and an extended configuration suitable for installation in a gas transport arrangement. Both the inner sleeve and the outer sleeve are of a predetermined thickness rendering the duct substantially rigid when in an extended configuration and enabling the duct to maintain its substantial rigidity upon extension from a compacted configuration. Optionally, at least one of the sleeves further includes a second, plastic layer bonded to the aluminum foil ribbon layer.