Typical air duct systems installed in American homes have excessive amounts of air leakage from poor duct connections that results in wasted energy and poor indoor air quality. The combination of air leakage and conduction losses results in losses of approximately 40% to 50% of the energy delivered to the duct system. This leakage problem is compounded by poor installation techniques in securing and sealing joints between the duct sections. This project will develop a new snap together design to eliminate air leakage at the connection points and provide a positive locking means of securing the duct sections. These features will be incorporated while main-taining a competitive cost compared to current designs. In Phase I, a duct system connection methodology was designed that eliminates virtually all air leakage and provides a positive locking connection. Prototype snap together duct fittings were constructed and tested to confirm both the leakage characteristics and the mechanical fastening abilities. Phase II will finalize component designs with manufacturers in order to produce a test run of components. HVAC contractors will be trained and the duct systems will be installed in two housing subdivisions, one in the Midwest and one the Western United States. A cost benefit analysis will be performed, and any design changes necessary for production will be made.

Commercial Applications and Other Benefits as described by the awardee. The new design will provide a guaranteed means of installation of air tight duct systems in American homes and small businesses. Introduction of the new design into the market should result in substantial energy savings for the American public. Additional benefits include improved comfort and indoor air quality, monetary savings on energy expenditures, and reduced production of green house gases and other emissions.