Undulated surface enhancement of diffuser blades for round and rectangular ceiling diffuser
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Solution Overview
Problem
Traditional HVAC diffusers have inefficient air distribution and high manufacturing costs due to their blade designs, which lead to increased energy consumption and noise levels.
Innovation Solution
The development of a diffuser blade with an undulated surface enhancement along its leading edge, fabricated from sheet metal, which reduces pressure drop and noise by improving air flow velocity and pressure profiles, and is cost-effective to manufacture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional flat blade designs are used, then manufacturing is simpler, but air flow distribution efficiency deteriorates
Solution Approach 1:
The patent applies curvature to the blade leading edge by introducing an undulated surface with multiple peaks and valleys. This curved geometry optimizes air flow attachment and distribution efficiency while maintaining compatibility with standard sheet metal fabrication processes, thus resolving the contradiction between manufacturing simplicity and air flow efficiency.
2Ease of manufacture
If traditional blade designs are used, then manufacturing costs are lower, but energy consumption increases
Solution Approach 1:
The undulated leading edge geometry improves air flow attachment and reduces turbulence, enabling more efficient air distribution. This reduces the power required by blowers and fans while the blade itself remains manufacturable using conventional sheet metal processes, thus resolving the energy consumption vs. manufacturing cost contradiction.
3Device complexity
If traditional blade designs are used, then manufacturing is less complex, but noise levels increase
Solution Approach 1:
The undulated surface geometry with multiple peaks and valleys optimizes air flow attachment and reduces turbulence-induced noise. Despite the increased surface complexity, the blade structure remains manufacturable using standard sheet metal forming techniques, thus resolving the noise reduction vs. structural complexity contradiction.
4Stress or pressure
If traditional blade designs are used, then pressure drop is higher, but manufacturing precision requirements are lower
Solution Approach 1:
The undulated leading edge geometry reduces pressure drop by optimizing air flow attachment. The curvature features can be fabricated using conventional sheet metal rolling and forming processes without requiring ultra-precise manufacturing tolerances, thus resolving the pressure drop reduction vs. manufacturing precision contradiction.
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 undulated surface enhancement on the diffuser blade reduces energy consumption by minimizing the impact on air flow pressure and velocity profiles, leading to lower operational power requirements for blowers or fans and decreased noise levels.
Implementation Method 1
The undulated contour extends into and out of the width... improving air flow velocity and pressure profiles
Data Source
AI summary
A round or rectangular ceiling diffuser includes a blade. The blade includes a leading edge configured to face an incoming air flow and having an undulated contour extending along a closed-loop formed by the blade. The blade also includes a trailing edge opposite to the leading edge, where a width of the blade extends from the leading edge to the trailing edge and the undulated contour extends into and out of the width.