Three-Sided Insulation Envelope for Existing Uninsulated Ductwork

Solution Overview

Problem

Uninsulated thermal distribution ductwork systems in commercial and residential buildings experience significant thermal losses due to leakage, conduction, and solar radiation, leading to uneven temperature distribution and reduced energy efficiency.

Innovation Solution

A three-sided insulation envelope is formed to encapsulate sections of uninsulated ductwork, using a duct board with V-shaped grooves to create a cavity and seat an insulation cap, thereby sealing the opening and reducing thermal losses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If existing uninsulated ductwork is left as-is, then installation complexity is minimal, but thermal losses increase significantly

Engineering Contradiction:

Improvethermal lossVSAvoidinsulation structure complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The insulation system is divided into modular components: a three-sided insulation envelope that wraps around the ductwork and a separate insulation cap that seals the opening. This segmentation allows the insulation to be applied in sections along the duct run, making the insulation process manageable and adaptable to different duct configurations while effectively reducing thermal losses.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulation envelope is designed to wrap around and enclose the existing ductwork, with the insulation cap nesting at the opening end to complete the seal. This nested configuration allows the insulation structure to adapt to the duct's geometry while maintaining effective thermal enclosure.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Loss of energy

If insulation is added to existing ductwork, then thermal losses are reduced, but installation difficulty increases

Engineering Contradiction:

Improvethermal lossVSAvoidinstallation ease

Core Design Contradiction:

Loss of energyVSEase of operation

Solution Approach 1:

By dividing the insulation into a three-sided envelope and a separate cap component, the system can be installed in simple sequential steps: first wrapping the envelope around the duct, then adding the cap at the opening. This segmentation transforms a potentially complex full-enclosure insulation job into manageable sections that can be applied to existing ductwork without requiring duct shutdown or complex fabrication.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Rather than attempting to insulate the entire duct enclosure at once or requiring access to all sides of the duct, the invention applies insulation to three sides and seals the fourth side with a cap. This inverted approach of insulating partial surfaces and sealing the remainder simplifies installation on existing ductwork where full access may not be available.

Inventive Principle:

Principle #13The other way round (Inversion)

3Loss of energy

If long duct runs are exposed to sunlight and high outdoor temperatures, then thermal losses increase, but adding insulation increases structural complexity

Engineering Contradiction:

Improvethermal lossVSAvoidinsulation structure complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The insulation system is divided into modular components: a three-sided insulation envelope that wraps around the ductwork and a separate insulation cap that seals the opening. This segmentation allows the insulation to be applied in sections along the duct run, making the insulation process manageable and adaptable to different duct configurations while effectively reducing thermal losses.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulation envelope is designed to wrap around and enclose the existing ductwork, with the insulation cap nesting at the opening end to complete the seal. This nested configuration allows the insulation structure to adapt to the duct's geometry while maintaining effective thermal enclosure.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 insulation assembly effectively reduces thermal losses and maintains air flow without disrupting the existing ductwork, improving energy efficiency and interior thermal comfort by encapsulating uninsulated ductwork sections.

Implementation Method 1

The insulation assembly includes a three-sided insulation envelope configured to form a cavity. The cavity is configured to receive a section of uninsulated, existing ductwork... thereby encapsulating the uninsulated, existing ductwork and sealing the opening

Methodology Applied

Scientific EffectThermal Insulation: Thermal Insulation

Data Source

PatentUS11473810B2Insulation structures, systems and methods for uninsulated existing ductwork

Publication Date: 2022.10.18 LANCIAUX FRAN

AI summary

An insulation assembly is provided. The insulation assembly includes a three-sided insulation envelope configured to form a cavity. The cavity is configured to receive a section of uninsulated, existing ductwork. The three-sided insulation envelope forms an opening. An insulation cap is configured to seat against the three-sided insulation envelope thereby encapsulating the uninsulated, existing ductwork and sealing the opening.