AU743294B2

AU743294B2 - Flexible ventilation ducting/conduit which incorporates branch conduit connector portions

Info

Publication number: AU743294B2
Application number: AU28074/99A
Authority: AU
Inventors: Thomas Reich
Original assignee: T & S Manufacturing Pty Ltd
Current assignee: AIR DIFFUSION AGENCIES Pty Ltd
Priority date: 1998-05-12
Filing date: 1999-05-12
Publication date: 2002-01-24
Anticipated expiration: 2019-05-12
Also published as: AU2807499A

Description

Regulation 3.2

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name of Applicant: T&S Manufacturing Pty Ltd (ACN 079 795 814) o •Actual Inventor: Thomas Reich Address for Service: MADDERNS, 1st Floor, 64 Hindmarsh Square, Adelaide, South Australia, Australia Invention title: "Flexible Ventilation Ducting/Conduit Which Incorporates Branch Conduit Connector Portions" Details of Associated Provisional Application No: Application No PP 3467 filed 12 h May 1998.

The following statement is a full description of this invention, including the best method of performing it known to us.

Acua Inetr hoaec Adrs fo evc: C-MDEN,1t*lo,6 idas qae Adlie Sot Autai, utai Ineto til:"lxbeVniaio utn/odi hc Inopoae Brnc Codi oncootos Deal of AsoitdPoiinlApiainN:ApiainN P36 fie 12 a*98 Th folwn ttmn*safuldsrpino*hsivetoicuigtebs This invention relates to flexible air conditioning ducting/conduit, and in particular to a connector assembly having a plurality of flexible collapsible tubular connector portions which can be respectively joined to lengths of flexible branch ducting/ conduit.

It is well known in the air conditioning industry to use flexible duct/conduit core wherein a helically wound reinforcing wire coil is covered by a strip of flexible material, eg plastics sheet, which is bonded, eg by welding, to the wire, for air conditioning ducting laid in the ceilings of homes and buildings. An insulating layer of foam and metal foil, eg aluminium foil, is normally wrapped around the core to form the ducting/conduit. The advantage of such flexible ducting is that it is inexpensive to produce, light weight and convenient for packaging and transport purposes due to the fact that it can be readily collapsed or compressed in a concertina fashion to a reduced compact form. It will of course be appreciated that air conditioning systems, particularly in large buildings or homes, require large lengths of ducting/conduit to be laid in the ceiling space. The handling of the lengths of ducting is made far easier for the installer by having the ducting packaged in small ooeo compact packages, which, when unwrapped, can be readily and easily lengthened S. out during the installation procedure.

It is also well known for adjacent lengths of flexible ducting to be joined together by means of rigid Y-shaped connectors. An example of such a connector is described and illustrated in Australian Patent 630256 (Heatshield). Another known type of Y-connector is moulded of rigid plastics material. While these rigid type of connectors function quite satisfactorily in terms of joining together adjacent lengths of flexible ducting, they do have their disadvantages. In particular they are of substantial size which is generally inconvenient for packaging and transport purposes. Due to their rigidity they cannot be collapsed to a smaller form as can be done with the lengths of flexible ducting. In addition, the transportation of such bulky connectors to their installation sites is generally inconvenient.

It is an object of the present invention to provide a connector assembly for connecting together lengths of flexible air conditioning ducting of the aforementioned type which is inexpensive to construct and assemble, is of lightweight construction, and is very easy for an installer to handle during the installation procedure.

It is another object of the present invention to provide an improved flexible duct assembly which includes tubular connector portions for connecting adjoining sections of ducting, as an integral part of the assembly, and wherein the connector portions are themselves collapsible to enable the whole assembly to be readily collapsed into a small compact configuration for packaging and transport purposes.

Broadly according to this invention therefore, there is provided a flexible ducting connector assembly comprising a first flexible tubular connector portion having a central axis which extends in a generally longitudinal direction, at least two flexible tubular branch duct connector portions, each of said at least two branch duct connector portions having its inner end joined around the perimeter thereof, by fastener means to at least one other branch duct connector portion and also to said inner end of said first connector portion, wherein the central .I 20 axis of each said connector portion is angled with respect to the axes of the other connector portions, and wherein said connector portions each comprise a continuous coil of reinforcing wire helically wrapped with and bonded to a flexible sheet material so as to form an axially collapsible tube.

The lengths and diameters of the connector portions can all be the same or different.

Generally, the diameters of the branch duct connector portions will be smaller than the diameter of the first connector portion.

Desirably, the adjacent ends of the connector portions are fastened together around their perimeters using metal staples which are applied by means of a conventional hand crimping tool or staple gun. Each of the staples is crimped so as to form a metal ring around sets of two (or more) adjacent convolutions of reinforcing wires of the connector portions. The fasteners securely fasten together the respective sets of reinforcing wires and thereby ensure that the connector portions are securely attached around their perimeters to each other.

The number of branch duct connector portions leading from the first large diameter connector portion can vary. Normally, two, three or four connector portions will be used depending on the ducting layout required for the building.

Generally, the first connector portion will connect to a main supply conduit which is attachable at its leading end to an outlet spigot at the base of a dropper unit which itself connects to the air conditioning unit mounted, for example, on the roof of a house. The branch connector portions are attachable to respective lengths of branch ducting/ conduits which convey conditioned air to an air register in the ceiling of a room in the home or building.

Preferably, lengths of conventional flexible branch ducting/ conduits are respectively *..attached to the flexible tubular connector portions in a spigot-socket type relationship by means of attachment clips spaced circumferentially around the join, each clip having an inner clip portion for attachment to a perimeter edge portion of a respective said connector portion, and an outer clip portion for attachment to a leading edge portion of the branch conduit, the inner and outer clip portions opening in opposite directions. Due to the flexibility and resiliency of the reinforcing wires of the connector portions, their open outer ends can be readily reduced in diameter to enable them to be compressed and inserted within the leading open end of a branch conduit, while at the same time clipping the two ends together by means of the attachment clips which are axially engaged.

Preferably each of the clip portions is provided with a series of ratchet teeth which are design to ensure that, with the clips attached, the overlapping ends of the flexible ducting portions being joined, are securely held together and will not inadvertently separate.

It will of course be appreciated that different forms of fasteners or clips can be used in order to fastener together adjacent end portions of the flexible branch conduits and the flexible connector portions.

According to another aspect of the invention, there is provided a method of producing a connector assembly for interconnecting lengths of flexible air conditioning ducting, comprising the steps of: providing at least three individual lengths of axially collapsible flexible ducting each formed by a continuous coil of reinforcing wire helically wrapped with and bonded to a flexible sheet material, one of the lengths constituting a main duct connector portion with the remaining lengths constituting two or more branch duct connector portions, (ii) joining by mechanical means a perimeter edge portion of the inner end of each of the branch duct connector portions to a respective perimeter end portion of the main duct connector portion, (iii) joining by mechanical means each one of the branch duct connector portions to at least one other of said branch duct connector portions along adjacent Soinner end peripheral edge portions thereof, 20 to thereby form a flexible duct connector assembly wherein one end of the main duct connector portion has joined to it around the perimeter thereof a plurality of branch duct connector portions each having a central axis which is angled with respect to the axis of the main duct connector portion and to each other.

While, the lengths of the connector portions will normally be short, with each one S attaching to a separate length of flexible ducting, it should be appreciated that the length of each connector portion can be selected so that its outer end can connect directly to a dropper outlet spigot or an air register outlet in the ceiling, without the need for any additional lengths of ducting to be utilised.

Desirably, the branch duct connector portions have central axes which extend, approximately at equal angles to the central axis of the main duct connector portion.

In order to further explain the present invention, several embodiments of the invention are described hereunder in more detail with reference to and illustrated in the accompanying drawings in which: Figure 1 is a perspective view of a 3-way connector assembly which has three flexible tubular connector portions which are angled with respect to one another and which are arranged for attachment to respective separate branch ducting/conduits; Figure 2 is a front elevational view of the assembly shown in Figure 1 and illustrating the manner in which the angled tubular connector portions are connected to one another and to the open distal end of the larger diameter connector portion; Figure 2a is an enlarged view which illustrates the manner in which the sets of reinforcing wires are stapled together; Figure 3 is a fragmentary exploded perspective view showing how a branch conduit is joined to one of the connector portions by means of a plurality of attachment clips S. (one only being shown); Figure 4 is a perspective view of the attachment clip shown in Figure 3; Figure 5 is a view of a 4-way connector assembly wherein a large diameter duct has joined to one end thereof three smaller diameter branch duct connector portions; while Figure 6 is a view similar to Figure 5 showing a large diameter duct connector which splits into four smaller diameter branch duct connector portions.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to the embodiment shown in Figures 1 and 2 of the drawings, a flexible duct connector assembly 10 comprises a flexible, tubular, large diameter connector member 11 to which is attached at one of its open ends a pair of flexible tubular smaller diameter connector members 12, 12' in a manner so as to form an approximately Y configuration. Each of the members 11, 12, 12' is comprised of a continuous coil of reinforcing wires 13, 14, 15 respectively helically wrapped with and bonded to flexible sheet material eg polythene or laminated aluminium foil, so as to form an axially collapsible tube (such flexible ducting being well known in the art).

The extended lengths of the members 11, 12, 12' may be substantially the same or substantially different to one another.

The connector members 12, 12' are securely fastened to one end of member 11 by metal staples 17 which are crimped, by means of a conventional hand crimping or stapling tool, around adjacent sets of reinforcing wires 13, 14, 15 located at the ends of the members 11, 12, 12' and which have been bunched together prior to crimping.

In the case of each of the connector members 12, 12' an inner end perimeter portion is fastened to an end perimeter portion of member 11, while its remaining perimeter portion is fastened to an adjacent end perimeter portion of the adjacent connector members 12, 12'. At least two, sometimes three, convolutions of the reinforcing wires 20 13, 14, 15 can be bunched together in order to effect the stapled connections (refer Figure 2a).

As shown in Figure 1, with the connector members 12, 12' fastened to the connector member 11 in a Y-configuration, interstitial gaps 20 of approximately triangular shape are created on opposite sides of the assembly 10. These gaps 20 can be sealed S. off by means of adhesive tape applied to the inside (or outside) surfaces of the members 11, 12,12'.

In accordance with known art, member 11 and part of the connector members 12, 12' can, if appropriate, be insulated by means of an intermediate layer of insulative material, eg plastics foam, and an outer wrapping of aluminium foil. In this case, however, the foil can be cut and shaped in the region of the joints between the 7 members 11, 12, 12' so as to form flaps (not shown) which wrap partially around the inner end regions of the connector members 12, 12' and which are joined together in the central valley region between the connector members 12, 12' by means of adhesive tape.

Referring to Figures 3 and 4 of drawings, each of the connector members 12, 12' is joined to an adjoining length of flexible branch ducting 21 by means of resilient attachment clips 22 which are spaced around the join. The mating ends 23, 24 of the connector member 12 and ducting 21 respectively overlap one another with the open end 23 of the connector 12 being reduced in diameter eg by deforming the wire convolutions, so as to fit within the open end 24 of the branch conduit 21. Each of the clips 22 has an inner clip portion 25 which is clipped onto the end 23 of the connector portion 12 by axially sliding an edge portion of end 23 into the slot defined by the clip portion 25. An outer clip portion 26 clips onto a peripheral edge portion of the conduit 21 in a similar manner. Ratchet type teeth 28 on the inner faces of the clip portions 25 and 26 ensure that the mating ends of the flexible duct members 12, 21 when engaged with the clip 22 are securely fastened together and will resist separation by virtue of the engagement of the reinforcing wires against the trailing faces of the ratchet teeth 28.

In order to assemble the duct core assembly 10 shown in Figure 1, the three lengths of duct members 11, 12 and 12' are laid in their collapsed form on a table in an approximately straight line with members 12, 12' located on opposite sides of the main duct 11 with their edges touching. The upper ends of members 12, 12' are stapled or clipped to the upper open end of the main duct 11 at diametrically opposed regions thereof. Normally one or two reinforcing wire convolutions from each member 11, 12, 12' are bunched together and then fastened by crimping a metal staple 17 therearound. The outer sides of the two connector members 12, 12' are then swung upwardly and inwardly over the open end of the main duct 11 until they abut one another whereupon the abutting perimeter edge portions are stapled or clipped in a similar manner described previously. Thereafter each of the connector members 12, 12' are fastened to the end of the connector member 11 by progressively crimping starting from the location where the first join was made and then working inwards around the perimeter of each end of the members 12, 12'. This involves the stapling of adjacent end peripheral edge portions of the connector members 12, 12' and the member 11 and thereafter between adjacent inside edge portions of the ends of the connector members 12, 12'. Where the three edge regions meet, it will normally be necessary to slightly kink the reinforcing wires so that they are bunched closely together before stapling around the triangular join.

The join between the perimeter end portions of the connector members 12, 12' ideally should locate as near as possible to the diametral plane passing through the outermost fasteners 17' on the outer sides of the member 11 (refer Figure 1).

The resilient flexible nature of the reinforcing wires 13, 14, 15 contained within the walls of the members 11, 12, 12' enables the wires to be quite easily deformed which in turn facilitates the joining together of their end peripheral edge portions. This is particularly so for the central join line formed between the inside edge portions of the ends of the connector members 12,12'.

Referring to the embodiment illustrated in Figure 5 of the drawings, the connector 20 assembly 30 comprises a main large diameter connector member 31 to one end of which is attached three branch conduit connector members 32 each of which is fastened around an inner end peripheral edge portion thereof to each adjacent connector member 32 by means of staples 34. The attachment of the fastening staples 34 to adjacent sets of reinforcing wires at the end peripheral edge portions of the members 31, 32 is performed in essentially the same manner as described in relation to the embodiment shown in Figure 1. In this embodiment the three connector members 32 are approximately symmetrically disposed around the central axis of the main connector member 31, with the central axis of each of the connector members 32 being inclined to the diametral cross-section or plane of the member 31.

In the embodiment shown in Figure 6 of the drawings, the ducting 36 comprises a main large diameter connector member 37 to which is attached at one end thereof four angled relatively small diameter branch conduit connector members 38. Once again the method of attachment of each of the connector members 38 to the inner end of the main duct member 37 is similar to that described previously.

Due to the fact that the reinforcing wire used in the construction of the duct portions can be easily deformed, it is possible for the distal end of the main connector member to be shaped as a square or rectangle (from its circular shaped) so as to fit directly onto a square outlet spigot on a dropper (rather than utilising an adaptor) refer Figure In order to make the ducting reasonably air tight and therefore prevent the leakage of air therefrom, the stapled joins can be covered by an adhesive tape it being appreciated that the stapling procedure will result in puncture holes being formed in the sheet material which form the walls of the ducting.

In a variation to the above-described embodiments, the main duct connector portion can itself be a length of ducting, with the branch duct connector portions being attached to one end thereof as an integral part of the ducting. This avoids the need S for a separate length of ducting to be joined to the assembly during installation.

A brief consideration of the above described embodiments will indicate that the invention provides for an extremely simple and inexpensive means for producing a connector for joining together lengths of flexible ducting. Furthermore, the flexible compressible/collapsible nature of the connector of this invention enables it to be collapsed to a relatively small size which is extremely convenient for packaging and S. transportation.

o•.

Claims

1. A flexible, collapsible connector assembly for joining together lengths of flexible ducting in an air conditioning system, comprising a first flexible tubular connector portion having a central axis which extends in a general longitudinal direction, and at least two flexible tubular branch duct connector portions, each of which is joined by fastener means around the perimeter of its inner end to at least one other branch duct connector portion and also to an inner end of said first connector portion, each said branch duct connector portion having its central axis angled with respect to the central axis of the first connector portion and to the axis or axes of the other branch duct connector portion(s), and wherein said connector portions each comprise a continuous coil of reinforcing wire helically wrapped with and bonded to a flexible sheet material so as to form an axially collapsible tube.

2. A connector assembly according to claim 1 wherein each of the branch duct connector portions is fastened around its inner end perimeter by means of metal S* fasteners to an end perimeter portion of each adjacent said branch duct connector 20 portion and also to a perimeter end portion of said first connector portion.

A connector assembly according to claim 2 wherein each said metal fastener is crimped around adjacent sets of convolutions of said reinforcing wires in the walls of the connector portions.

4. A connector assembly according to claim 1 wherein there are two, three or four branch duct connector portions.

A connector assembly according to any one of claims 1 to 4 wherein the diameter of the connector portions are the same or different.

6. A connector assembly according to any one of the preceding claims further comprising attachment clips for joining each of the outer ends of the connector portions to respective lengths of branch ducting/conduits.

7. A connector assembly according to claim 6 wherein each said attachment clip has an inner clip portion for attachment to a free perimeter edge portion of a respective said connector portion, and an outer clip portion for attachment to a leading edge portion of respective said branch ducting, said inner and outer clip portions opening in opposite directions, said connector portion having its outer end adapted to engage within the open leading end of its associated said branch ducting so that their adjacent ends overlap.

8. A connector assembly according to claim 7 wherein each said clip portion is provided on an inner face thereof with a plurality of transversely extending spaced apart ratchet teeth.

9. A connector assembly according to any preceding claim wherein the lengths of said connector portions are large in comparison to their diameters. .i 20

10. A method of producing a connector assembly for interconnecting lengths of flexible air conditioning ducting, comprising the steps of: providing a plurality of individual lengths of flexible tubular axially collapsible ducts each comprising a continuous coil of reinforcing wire helically wrapped with and bonded to a flexible sheet material, one of the lengths constituting a first duct with the remaining lengths constituting two or more branch forming Sducts, (ii) joining by mechanical fasteners each one of the branch forming ducts to at least one other said branch forming duct along inner end peripheral edge portions thereof, and (iii) joining by mechanical fasteners a further inner end peripheral edge portion of each of the branch forming ducts to a respective end perimeter portion of the first duct, to thereby form a flexible connector assembly wherein the first duct has joined to one of its ends around the perimeter thereof a plurality of branch forming ducts each having a central axis which is angled with respect to the axis of the first duct.

11. A method according to claim 10 wherein the lengths of the ducts are short and constitute connector portions for connection to separate lengths of similar flexible branch ducting/conduit.

12. A method according to claim 10 or claim 11 wherein the step of joining is effected by means of metal staples which are applied by a hand crimping tool or staple gun.

13. A method according to claim 12 wherein each of the metal staples is crimped so as to form a metal ring around adjacent sets of two or more adjacent convolutions :°eooo of the reinforcing wires contained within the walls of the ducts. *o*o 20

14. A method according to any one of claims 10 to 13 wherein there are two, three or four branch forming ducts attached around perimeter portions thereof to the inner end perimeter of said first duct. S

15. A connector assembly for air conditioning ducting substantially as hereinbefore described with reference to and as illustrated in Figures 1 and 2; Figure S. 5; or Figure 6 of the accompanying drawings.

16. A method of producing a connector assembly for flexible air conditioning ducting substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings. Dated this 12th day of May, 1999. T&S MANUFACTURING PTY LTD By its Patent Attorneys MADDERNS 0:.6 :.66 a* 0