CA2807396C - A method of making a duct member - Google Patents
A method of making a duct member Download PDFInfo
- Publication number
- CA2807396C CA2807396C CA2807396A CA2807396A CA2807396C CA 2807396 C CA2807396 C CA 2807396C CA 2807396 A CA2807396 A CA 2807396A CA 2807396 A CA2807396 A CA 2807396A CA 2807396 C CA2807396 C CA 2807396C
- Authority
- CA
- Canada
- Prior art keywords
- sheet
- edge
- catch
- panel
- tray
- 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
Links
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F13/00—Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening
- F24F13/02—Ducting arrangements
- F24F13/0245—Manufacturing or assembly of air ducts; Methods therefor
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F13/00—Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening
- F24F13/02—Ducting arrangements
- F24F13/0209—Ducting arrangements characterised by their connecting means, e.g. flanges
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Duct Arrangements (AREA)
- Rigid Pipes And Flexible Pipes (AREA)
- Details Of Indoor Wiring (AREA)
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
A Method of Making a Duct Member Field of the Invention 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.
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 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 member.
It is an object of the present invention to provide an improved method of making a duct member.
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 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
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 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 member.
It is an object of the present invention to provide an improved method of making a duct member.
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 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
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 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.
Brief Description of the Drawings Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
Figure 1 shows a duct panel produced according to an embodiment of the present invention.
Figures 2 and 2(a) show detailed views of assembled ducting including the duct panels of Figure 1.
Description of Embodiments of the Invention 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(b) 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).
As in WO 2010/094385 Figure 8, the panel 100 has male and female catches respectively running along opposite parallel
Brief Description of the Drawings Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
Figure 1 shows a duct panel produced according to an embodiment of the present invention.
Figures 2 and 2(a) show detailed views of assembled ducting including the duct panels of Figure 1.
Description of Embodiments of the Invention 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(b) 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).
As in WO 2010/094385 Figure 8, the panel 100 has male and female catches respectively running along opposite parallel
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 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 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.
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 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 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 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
2010/094385 Figure 8 and, accordingly, the same reference numerals have been applied. The following description will 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 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.
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 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 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 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
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.
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 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 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 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), 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 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
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 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 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 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), 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 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
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-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.
The invention is not limited to the embodiments described herein which may be modified or varied without departing from the scope of the invention.
In addition or as an alternative to the layer 114, an anti-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.
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 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 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 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 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.
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.
fitting flanges to the transverse cut ends of each panel for fixing each panel to the transverse cut end of an adjacent panel.
Applications Claiming Priority (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 |
|---|---|
| CA2807396A1 CA2807396A1 (en) | 2012-02-23 |
| CA2807396C true CA2807396C (en) | 2018-02-27 |
Family
ID=44629154
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2807396A Active CA2807396C (en) | 2010-08-17 | 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 (2)
| 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 |
| JP6577294B2 (en) * | 2015-08-25 | 2019-09-18 | 株式会社イノアックコーポレーション | Connecting unit and duct construction method |
Family Cites Families (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| SE347174B (en) * | 1970-02-23 | 1972-07-31 | Svenska Flaektfabriken Ab | |
| DE2445443C2 (en) * | 1974-09-24 | 1983-02-24 | Ltg Lufttechnische Gmbh, 7000 Stuttgart | Wall parts for the construction of walls, chambers, air ducts or the like of ventilation systems |
| 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 |
| JPS62132615A (en) * | 1985-12-06 | 1987-06-15 | Toho Shiitofureemu Kk | Manufacture of fire resistant panel based on composite metal source |
| IT1264920B1 (en) * | 1993-07-12 | 1996-10-17 | Covenco S R L | QUICK CONNECTION JOINT DEVICE PARTICULARLY FOR DUCTING FOR AIR CONDITIONING EQUIPMENT |
| US5450879A (en) * | 1994-06-14 | 1995-09-19 | Met-Coil Systems Corporation | Cornerless slip-on flange system for duct connections |
| DE19839416C2 (en) * | 1998-08-29 | 2002-06-20 | H & K Teckentrup Kg | Process for producing a sheet metal hollow profile for roller doors or the like |
| JP3625801B2 (en) * | 2002-01-23 | 2005-03-02 | 株式会社フカガワ | Goby structure for duct assembly |
| 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 | 支亮 | Pipeline provided with connecting components and manufacturing method thereof |
| AU2010214924B2 (en) * | 2009-02-18 | 2015-10-22 | 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 |
-
2011
- 2011-07-27 CA CA2807396A patent/CA2807396C/en active Active
- 2011-07-27 EP EP11736370.5A patent/EP2567156B1/en active Active
- 2011-07-27 JP JP2013524400A patent/JP5809269B2/en active Active
- 2011-07-27 CN CN201180038882.5A patent/CN103069224B/en active Active
- 2011-07-27 ES ES11736370T patent/ES2436192T3/en active Active
- 2011-07-27 AU AU2011290865A patent/AU2011290865B2/en active Active
- 2011-07-27 WO PCT/EP2011/062930 patent/WO2012022594A1/en not_active Ceased
Also Published As
| Publication number | Publication date |
|---|---|
| EP2567156B1 (en) | 2013-09-25 |
| WO2012022594A1 (en) | 2012-02-23 |
| ES2436192T3 (en) | 2013-12-27 |
| AU2011290865A1 (en) | 2013-02-28 |
| JP2013535656A (en) | 2013-09-12 |
| AU2011290865B2 (en) | 2016-03-31 |
| CN103069224A (en) | 2013-04-24 |
| CN103069224B (en) | 2015-12-02 |
| EP2567156A1 (en) | 2013-03-13 |
| CA2807396A1 (en) | 2012-02-23 |
| JP5809269B2 (en) | 2015-11-10 |
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