Folded Sheet-Metal Duct Assembly for Low-Volume Shipping
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Solution Overview
Problem
Existing ducting systems face high costs in workshop fabrication, storage, handling, and transportation due to large cross-sections, requiring expensive machinery and processes, and incur significant costs in shipping and on-site handling.
Innovation Solution
The duct member is assembled using resilient catches formed by folding sheet metal panels, where each catch includes a compressible material to maintain engagement and seal the joints, allowing for efficient mass production and reduced material and labor costs, with panels designed for easy assembly and reduced volume for shipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ducting is fabricated in a workshop using machines such as guillotines, press brakes and seamers, then manufacturing precision is improved, but device complexity and production cost increase
Solution Approach 1:
The ducting system is segmented into modular components: flat panels with integrated catches that can be independently manufactured and then assembled on-site. This eliminates the need for complex workshop machinery while maintaining manufacturing precision through standardized panel production.
Solution Approach 2:
The catches are designed to be self-forming through folding operations on the panels themselves, rather than requiring separate machining operations. The panels are self-sufficient with integrated joining mechanisms, eliminating the need for external seamers and press brakes.
2Quantity of substance
If large duct cross sections are used, then air and gas distribution capacity is improved, but storage and shipping volume increase
Solution Approach 1:
Large duct cross-sections are segmented into multiple flat panels that can be stacked efficiently during storage and shipping. The panels occupy minimal space in their flat state but assemble into large cross-section ducts on-site, resolving the contradiction between distribution capacity and shipping volume.
3Strength
If traditional joining methods are used, then structural strength is improved, but assembly time and labor cost increase
Solution Approach 1:
The catches are pre-formed as integral parts of the panels during panel manufacturing, with detent surfaces and resilient bodies already in position. This preliminary action eliminates the need for time-consuming on-site joining operations while maintaining joint strength through precise pre-positioning of joining features.
Solution Approach 2:
The resilient catches automatically engage and lock panels together through their own elastic deformation, without requiring external fastening tools or additional labor. The self-service mechanism maintains strong joints while minimizing assembly time and labor cost.
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 approach reduces production and shipping costs, facilitates easier handling and assembly, and allows for mass production of ducting components with integral joints, lowering overall costs and improving logistics in air and gas distribution systems.
Implementation Method 1
at least one of the catches includes a body of resilient material compressed between the catches and biasing the catches apart to maintain the detent surfaces bearing against one another
Data Source
Figure 1
Figure 2(a)~2(c)
Figure 3
AI summary
A tubular duct member comprises a plurality of sheet metal panels (10, 12) joined along adjacent longitudinal edges by cooperating folded sheet metal catches (14, 16), the catches being pushed together such that respective detent surfaces (28, 30) on each catch engage behind one another to retain the edges of the sheets together. One of the catches (14) includes a body (36) of resilient material compressed between the catches and biasing the catches apart to maintain the detent surfaces (28, 30) bearing against one another.