AU2011290865B2 - A method of making a duct member - Google Patents

A method of making a duct member Download PDF

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Publication number
AU2011290865B2
AU2011290865B2 AU2011290865A AU2011290865A AU2011290865B2 AU 2011290865 B2 AU2011290865 B2 AU 2011290865B2 AU 2011290865 A AU2011290865 A AU 2011290865A AU 2011290865 A AU2011290865 A AU 2011290865A AU 2011290865 B2 AU2011290865 B2 AU 2011290865B2
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AU
Australia
Prior art keywords
sheet
form
edge
catch
method
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
AU2011290865A
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AU2011290865A1 (en
Inventor
Brian Rowan
Patrick Walsh
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Walsh Intellectual Property Ltd
Original Assignee
Walsh Intellectual Property Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to US12/857,733 priority Critical patent/US8695644B2/en
Priority to US12/857,733 priority
Application filed by Walsh Intellectual Property Ltd filed Critical Walsh Intellectual Property Ltd
Priority to PCT/EP2011/062930 priority patent/WO2012022594A1/en
Publication of AU2011290865A1 publication Critical patent/AU2011290865A1/en
Application granted granted Critical
Publication of AU2011290865B2 publication Critical patent/AU2011290865B2/en
Application status is Active legal-status Critical
Anticipated expiration legal-status Critical

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24FAIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F13/00Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening
    • F24F13/02Ducting arrangements
    • F24F13/0245Manufacturing or assembly of air ducts; Methods therefor
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24FAIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F13/00Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening
    • F24F13/02Ducting arrangements
    • F24F13/0209Ducting arrangements characterised by their connecting means, e.g. flanges

Abstract

A method of making a duct member comprises feeding sheet metal continuously from a roll, progressively folding the opposite edges of the sheet as it advances to form a respective folded metal catch (14', 16') along each edge. Each catch includes an upstanding wall (102, 104) defining with the main body (106) of the sheet a shallow tray across the width of the sheet. A thermal insulator is dispensed in flowable form into the shallow tray as the sheet advances so that the thermal insulator spreads out to fill substantially the full width of the tray between the upstanding walls. The liquid thereafter solidifies to form a solid thermally insulating layer (110). The sheet is cut transversely into individual panels (100) having a respective catch along each edge for in-use push fit connection to a cooperating catch along the edge of an adjacent panel.

Description

WO 20121022594 1 PCT/EP2011/062930 A Method of Making a Duct Member Field of the Invention 5 This invention relates to a method of making a duct member, i.e. a length of duct of which a number can be joined end to end to form tubular ducting for, e.g., air and gas distribution systems. 10 Background to the Invention WO 2010/094385 (PCT/EP2010/000433) published on 26 August 2010 discloses a tubular duct member comprising a plurality of sheet metal panels joined along adjacent longitudinal 15 edges by cooperating folded sheet metal catches. The catches are pushed together such that respective detent surfaces on each catch engage behind one another to retain the edges of the sheets together. In some embodiments, an insulating panel is fixed to the various panels of the duct 20 member. It is an object of the present invention to provide an improved method of making a duct member. 25 Summary of the Invention The present invention provides a method of making a duct member comprising feeding sheet metal continuously from a roll, progressively folding the opposite edges of the sheet 30 as it advances to form a respective folded metal catch along each edge, each catch including an upstanding wall defining with the main body of the sheet a shallow tray WO2012/022594 2 PCT/EP2011/062930 across the width of the sheet, dispensing a thermal insulator in flowable form into the shallow tray as the sheet advances so that the thermal insulator spreads out to fill substantially the full width of the tray between the 5 upstanding walls, the liquid thereafter solidifying to form a solid thermally insulating layer, and cutting the sheet transversely into individual panels having a respective catch along each edge for in-use push fit connection to a cooperating catch along the edge of an adjacent panel. 10 Brief Description of the Drawings Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in 15 which: Figure 1 shows a duct panel produced according to an embodiment of the present invention. 20 Figures 2 and 2(a) show detailed views of assembled ducting including the duct panels of Figure 1. Description of Embodiments of the Invention 25 Figure 1 shows a duct panel produced according to an embodiment of the present invention. Figure 1(a) is an underneath plan view of a duct panel 100, Figure 1(h) is a cross-section on the line B-B of Figure 1(a), and Figure 1(c) is an enlarged cross-section similar to Figure 1(b). 30 As in WO 2010/094385 Figure 8, the panel 100 has male and female catches respectively running along opposite parallel WO2012/022594 3 PCT/EP2011/062930 edges. These catches are constructed and operate generally the same as the male and female catches 14', 16' of WO 2010/094385 Figure 8 and, accordingly, the same reference numerals have been applied. The following description will 5 concentrate on the differences from WO 2010/094385, the basic operation of the catches being assumed. The main difference is that each catch 14', 16' includes a respective upstanding wall 102, 104 formed by additional 10 folding of the sheet metal at each edge of the panel through two 90 degree bends and one 180 degree bend, as shown in Figure 1(c). These walls 102 and 104, together with the main body 106 of the panel 100 as a base, form a shallow tray across the width of the panel. 15 The panels 100 are produced continuously from a roll of sheet metal, the edges of the sheet being progressively folded as the sheet advances from the roll to form the catches 14', 16' and the upstanding walls 102, 104, the 20 sheet then being cut transversely into individual panels. However, after the folding of the catches and the upstanding walls, but before the sheet is cut into individual panels, a liquid polyurethane (LPU) is continuously dispensed into the shallow tray formed by the 25 walls 102, 104 and the metal sheet. This flows sideways to fill the full width of the tray between the walls 102, 104 and rapidly cures (within minutes) to form a solid insulating layer 110. Longitudinal and transverse strengthening ribs 112 are formed in each panel by pressing 30 before the application of the LPU. Finally, end flanges 118 as shown in the assembly drawing of Figure 2 and the detailed view of Figure 2 (a), serving the same purpose as WO2012/022594 4 PCT/EP2011/062930 the integral flanges 18 in WO 2010/094385 Figures 1 to 4, are riveted (or alternatively spot welded) to the transverse cut ends of each panel for fixing each panel to an adjacent panel. 5 In the preceding embodiment a hard polymer lining 114 is optionally sprayed onto the exposed surface of the foam/insulating layer 110, Figure 1. This has two advantages. First, it provides a hardened surface which 10 serves to protect the underlying layer 110 when the ducts are being cleaned. Second, although the layer 110 has a certain amount of flame resistance, it can still be flammable. The hard polymer lining is a flame retardant, and provides a higher fire resistance than the underlying 15 material. The hard polymer layer 114 has a thickness of about 3mm, but could range in thickness from about 0.5mm, in contrast with the layer 110 which is typically 32mm-35mm thick but could be up to around 45mm thick. The flame retardant polymer 114 is preferably of the type produced by 20 BASF under the mark Elastocoat C6325/105; or by Bollom Fire Protection (UK) under the mark BroFlame. In embodiments of the invention where the assembled ducting, for example as shown in Figures 2 and 2(a), 25 includes an insulating layer 110 possibly coated with a polymer lining 114, a durable and relatively impervious internal lining is provided, by comparison with using for example Rockwool or equivalent as an insulator either within or around the ducting. This layer/lining does not 30 accommodate rodents or harbour or promote the spread of bacteria, such as Legionella as readily as prior art systems. At the same time, the ducting can be transported WO2012/022594 5 PCT/EP2011/062930 in flat packed form and when assembled can provide a relatively airtight conduit for use in many applications. In addition or as an alternative to the layer 114, an anti 5 microbial layer (not shown) can be added to the insulating layer 110. One suitable coating is produced by General Paints Ltd of Celbridge, Ireland under the mark Hygen Ultra. 10 The invention is not limited to the embodiments described herein which may be modified or varied without departing from the scope of the invention.

Claims (4)

1. A method of making a duct member comprising feeding sheet metal continuously from a roll, progressively folding 5 the opposite edges of the sheet as it advances to form a respective folded metal catch along each edge, each catch including an upstanding wall defining with the main body of the sheet a shallow tray across the width of the sheet, dispensing a thermal insulator in flowable form into the 10 shallow tray as the sheet advances so that the thermal insulator spreads out to fill substantially the full width of the tray between the upstanding walls, the liquid thereafter solidifying to form a solid thermally insulating layer, and cutting the sheet transversely into individual 15 panels having a respective catch along each edge for in-use push fit connection to a cooperating catch along the edge of an adjacent panel.
2. A method as claimed in claim 1, wherein the flowable 20 insulator comprises a liquid polymer which solidifies by curing to form the solid insulating layer.
3. A method as claimed in claim 2, wherein the polymer is liquid polyurethane. 25
4. A method as claimed in claim 1, further comprising: fitting flanges to the transverse cut ends of each panel for fixing each panel to the transverse cut end of an adjacent panel. 30
AU2011290865A 2009-02-18 2011-07-27 A method of making a duct member Active AU2011290865B2 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
US12/857,733 US8695644B2 (en) 2009-02-18 2010-08-17 Tubular duct member
US12/857,733 2010-08-17
PCT/EP2011/062930 WO2012022594A1 (en) 2010-08-17 2011-07-27 A method of making a duct member

Publications (2)

Publication Number Publication Date
AU2011290865A1 AU2011290865A1 (en) 2013-02-28
AU2011290865B2 true AU2011290865B2 (en) 2016-03-31

Family

ID=44629154

Family Applications (1)

Application Number Title Priority Date Filing Date
AU2011290865A Active AU2011290865B2 (en) 2009-02-18 2011-07-27 A method of making a duct member

Country Status (7)

Country Link
EP (1) EP2567156B1 (en)
JP (1) JP5809269B2 (en)
CN (1) CN103069224B (en)
AU (1) AU2011290865B2 (en)
CA (1) CA2807396C (en)
ES (1) ES2436192T3 (en)
WO (1) WO2012022594A1 (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2994472A1 (en) * 2012-08-10 2014-02-14 Raymond Guionie Ventilation duct for draining of wet wall in old house, has set of straight elements that are able to be sealed end to end to form duct of desired length, and set of folds arranged in section of duct for supporting air flow

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2445443A1 (en) * 1974-09-24 1976-04-01 Ltg Lufttechnische Gmbh Air conditioning plant - interlocking insulated hollow walling components, with two parallel croarms engaged by part of next component, and intermediate groove
DE19839416A1 (en) * 1998-08-29 2000-03-09 Tekla Technik Tor & Tuer Gmbh Hollow plate profile for roller gates etc is from a folded strip to give an inner chamber to be filled with an insulating foam and the profile shaped with upper and lower hook bars
JP2003214692A (en) * 2002-01-23 2003-07-30 Fukagawa:Kk Seam structure for assembling duct
KR100976079B1 (en) * 2009-05-18 2010-08-16 덕유패널 주식회사 A continuous phenol foam board and air conditioning duct by using the board
WO2010094385A1 (en) * 2009-02-18 2010-08-26 Walsh Intellectual Property Ltd. A tubular duct member

Family Cites Families (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SE347174B (en) * 1970-02-23 1972-07-31 Svenska Flaektfabriken Ab
JPS6034815A (en) * 1984-06-26 1985-02-22 Ishikawa Takashi Manufacture of composite panel for building
JPS6125810A (en) * 1984-07-16 1986-02-04 Toho Shiitofureemu Kk Continuous foam molding method of novolak type phenolic resin
JPH0333086B2 (en) * 1985-12-06 1991-05-15 Toho Sheet & Frame
IT1264920B1 (en) * 1993-07-12 1996-10-17 Covenco S R L Device for quick coupling particularly for joining ducts for air conditioning equipment
US5450879A (en) * 1994-06-14 1995-09-19 Met-Coil Systems Corporation Cornerless slip-on flange system for duct connections
JP3954978B2 (en) * 2002-04-01 2007-08-08 富士空調工業株式会社 Air conditioning duct unit
FR2894316B1 (en) * 2005-12-05 2011-04-15 Commissariat Energie Atomique Hot gas transport driving element and method for producing such a component
JP2009008276A (en) * 2007-06-26 2009-01-15 Kanaflex Corporation Knock-down duct
CN101373032A (en) * 2008-10-09 2009-02-25 亮 支 Pipeline provided with connecting components and manufacturing method thereof

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2445443A1 (en) * 1974-09-24 1976-04-01 Ltg Lufttechnische Gmbh Air conditioning plant - interlocking insulated hollow walling components, with two parallel croarms engaged by part of next component, and intermediate groove
DE19839416A1 (en) * 1998-08-29 2000-03-09 Tekla Technik Tor & Tuer Gmbh Hollow plate profile for roller gates etc is from a folded strip to give an inner chamber to be filled with an insulating foam and the profile shaped with upper and lower hook bars
JP2003214692A (en) * 2002-01-23 2003-07-30 Fukagawa:Kk Seam structure for assembling duct
WO2010094385A1 (en) * 2009-02-18 2010-08-26 Walsh Intellectual Property Ltd. A tubular duct member
KR100976079B1 (en) * 2009-05-18 2010-08-16 덕유패널 주식회사 A continuous phenol foam board and air conditioning duct by using the board

Also Published As

Publication number Publication date
ES2436192T3 (en) 2013-12-27
WO2012022594A1 (en) 2012-02-23
CA2807396C (en) 2018-02-27
EP2567156A1 (en) 2013-03-13
JP5809269B2 (en) 2015-11-10
CN103069224B (en) 2015-12-02
JP2013535656A (en) 2013-09-12
AU2011290865A1 (en) 2013-02-28
CN103069224A (en) 2013-04-24
CA2807396A1 (en) 2012-02-23
EP2567156B1 (en) 2013-09-25

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