WO2003033204A1

WO2003033204A1 - Apparatus for realizing connectors for ducts for air conditioning system and method thereof

Info

Publication number: WO2003033204A1
Application number: PCT/IB2002/004259
Authority: WO
Inventors: Giuseppe Librizzi
Original assignee: Giuseppe Librizzi
Priority date: 2001-10-17
Filing date: 2002-10-16
Publication date: 2003-04-24
Also published as: ITTO20010988A1

Abstract

Apparatus (1) for executing air conveying duct connectors (15;19;23) in environmental conditioning systems, comprising a basic structure (2), on which at least horizontal moving means (5,6) of an isolating panel (P) and cross traversing means (7,8,9,10,V,M) of a tool carrier (7) are provided. The invention is featured in that the horizontal moving means (5,6) and cross traversing means (7) are activated individually and/or associated to each other for the execution of shaped components (15',15C,15D,15E;19A,19B,19C,19D,19E,19C',19D',19E';23',23D;25S,25C) to obtain at least a connector (15;19;23) from said isolating panel (P).

Description

APPARATUS FOR REALIZING CONNECTORS FOR DUCTS FOR AIR CONDITIONING SYSTEM AND METHOD THEREOF.

DESCRIPTION

The present invention relates to an apparatus for executing air conveying duct connectors (15;19;23) in environmental conditioning systems, meaning by environmental conditioning a simple air heating and/or ventilation and/or renewal and/or recycling through air filters and/or air venting, as well as connectors executed with said apparatus.

The ducts employed in conditioning systems are generally executed using quadrangular or rectangular sections made from isolating material connected to each other; these ducts sections are typically made from hard foamed polyurethane panels, coated with thin aluminium foils. To this purpose, at least three V-shaped grooves representing the folding lines are executed on the surface of a flat panel made from isolating material; the panel is then folded over itself along said folding lines to form a quadrangular section; suitable angular sealing means (such as adhesive) are provided for fastening both panel end sides previously chamfered by 45° to each other, usually along a corner of the section.

Execution of the V-shaped grooves may be performed manually or by means of machines apt to this purpose, like the machine described in the Italian patent no.

01270410.

Connection between the various sections is performed according to common procedures, such as through the assembly of profiles on the section headers and the use of further profiles appropriately shaped, which are going to engage the profiles assembled on the headers and keep the sections connected to each other. The ducts executed this way usually extend over straight paths, both horizontal and vertical ones, which are connected to each other by means of angular connectors. Moreover, several ducts may depart from one main duct for air distribution to other directions; in this instance, a connector from the main duct to the ducts derived from it is required.

These connectors are made from a flat panel of foamed polyurethane like the one used for executing the duct sections. Since execution of these connectors is performed manually, the operator has to lay out the shape of the parts to be executed on the panel; also, the operator will have to draw the parts on the panel in such a way to minimize scraps for limiting the costs.

After cutting the parts, the operator also has to execute some V-shaped notches manually for folding purposes and a 45° chamfer on the edges to be joined together, so that the joint lays on the sharp corner.

At it can be easily noticed, the operation for arranging, cutting and chamfering these connectors is time requiring with consequent higher costs.

It is the aim of the present invention to solve the above drawbacks.

In this main frame, it is the object of the present invention to provide an apparatus and a method for executing air conveying duct connectors in conditioning systems, made from foamed material, in particular polyurethane, which are not subject to the drawbacks of the common art, but are such to ensure functional advantages and easy execution.

A further object of the present invention is to provide a simple efficient method for executing air conveying duct connectors in environmental conditioning systems.

A further object of the present invention is to provide an apparatus, in which the development of the angular connector is performed automatically.

One or more of the above aims are obtained according to the present invention by means of an apparatus for executing air conveying duct connectors in conditioning systems, and a method thereof for executing said connectors, as well as connectors executed accordingly, incorporating the features of the annexed claims, which form an integral part of the present description

Further objects, features and advantages of the present invention will become apparent from the following detailed description and annexed drawings, which are supplied by way of non limiting example, wherein:

- Fig. 1 shows schematically a side view partially in section of an apparatus for executing air conveying duct connectors in environmental conditioning systems, according to the invention;

- Fig. 2 shows schematically a front view of an apparatus for executing the connectors according to the invention; - Figs. 3, 3A and 3B show a view of a first connector type, in a semi-finished form and final form, executed according to the invention;

- Figs. 4 and 4A show a view of a second connector type, in a semi-finished form and final form, executed according to the invention;

- Figs. 5, 5A and 5B show a view of a third connector type, in a semi-finished form and final form, executed according to the invention;

- Figs. 6, 6A and 6B show a partial perspective view of the execution of a section of an air conveying duct in environmental conditioning systems, with a tapered end, in a semi-finished form and final form, according to the apparatus of the invention. In Fig. 1 , representing a side view partially in section of an apparatus for executing air conveying duct connectors in environmental conditioning systems according to the invention, reference 1 indicates the apparatus.

The apparatus 1 consists of a basic structure 2 formed by two side headers 2A, which are spaced and connected to each other by means of tension rods 3 and a double T- shaped profile 4. Reference 5 indicates two rollers connected to the side headers 2A; the rollers 5 are motor-driven and can rotate in both senses, i.e. clockwise and anti-clockwise.

Reference 6 indicates two idle rollers, each one placed over a motor-driven roller

5; also the rollers 6 are commonly connected the headers 2A. The rollers 5 and 6 are so spaced from each other for ensuring a way through and the entrainment of an isolating panel P to be machined. The gap between the rollers 5 and 6 may change depending on the thickness of the panel P.

Reference 7 indicates a tool-carrier with a support 8 solidly connected on its rear side; the carrier 7 can traverse horizontally by means of the rollers 9 fastened to the support 8 and sliding over two horizontal shafts 10.

With reference to Fig. 2 representing schematically a front view of an apparatus for executing the connectors according to the invention, references 11 and 12 indicate two work units fastened in front to the carrier 7. Both work units 11 and 12 have a tool on their lower end, i.e. the unit 11 carries a coned milling cutter 13 and the unit 12 a cylindrical milling cutter 14. The work units 11 and 12 can execute a vertical movement for approaching and/or moving away the relevant milling cutter from the panel P to be machined, independently from each other; motion is obtained through a common pneumatic system. Rotation of each milling cutter 13 and 14 is ensured by a relevant motor M assembled on each unit, not represented. The horizontal traverse of the carrier 7 is provided by a screw V placed horizontally with respect to the carrier 7 and commonly connected to it by means of a nut screw M fastened to the carrier 7.

The screw V is controlled by a direct current electric motor through a gear reducer. The use of a direct current motor will ensure reversal of the rotation sense through a simple power feed reverse for the traverse reverse of the carrier 7.

Downstream and upstream of the apparatus 1 some supporting planes, not represented in the figures, are used for supporting the panel P prior to and during its machining as well as for supporting the parts obtained from the panel P. The apparatus 1 is electrically and hydraulically connected by means of common procedures, not represented, to an electronic programmable and/or pre-selectable control system, supervising all the functions required for the apparatus operation. A plurality of connector types are stored in the electronic control system, to which further types can still be added, whose dimensions are given by the operator of the apparatus when starting the execution stage of the connector. With reference to Figures 3, 3A and 3B representing a view of a first connector type in a semi-finished form and final form according to the invention, reference 15 indicates a two-ways connector being apt to connect two ducts to each other for air conveyance in environmental conditioning systems. The connector 15 is formed by a duct section 16 and a second duct section 17 departs sideways from it for connecting the duct 15 to the second duct.

The connector 15 consists of a development 15' formed by a base 15A and two equal walls 15B reaching a perpendicular position to the base 15A and connected to it by means of the aluminium coating foil of the panel from which the connector is obtained.

An extension 17A departs from each one of the two walls 15B forming the connector section 17 for connection to the second duct. In the specific instance the second duct has a smaller size than the first duct from which it is derived.

In order to avoid any air flow chokes and improve air conveyance in the second duct, the outer wall 17B of the extension 17A has a semi-circular form ending over the edge of the wall 15B. Completion of the connector 15 will also require three bottoms for the side closure of the connector 15, indicated with 15C, 15D and 15E, respectively. Reference 18 indicates some 90° V-shaped notches for 90° folding of the side walls 15B with respect to the base 15 (Fig. 3A and 3B).

The edges of the walls 15B and extensions 17A to be connected to the bottoms edges, have a 45° chamfer for coupling to a matching chamfer on the bottoms edges, for their joining on a corner of the connector.

Connection of the bottoms 15C, 15D and 15E to the side walls 15B and extensions 17A is made with adhesive agents.

With reference to the Figures 4 and 4A representing a view of a second connector type in a semi-finished form and final form according to the invention, reference 19 indicates a three-ways connector being apt to connect three ducts to each other for air conveyance in environmental conditioning systems.

The connector 19 is formed by a duct section 20, from which a duct section indicated with 21 and 22, respectively, departs from each one of its two sides for connecting the connector 19 to a second and third ducts, respectively.

The connector 19 has two symmetric bases indicated with 19A and 19B, respectively, from which two extensions 21 A and 22A depart sideways for forming the duct sections 21 and 22 to connect the connector 19 to the second and third ducts. In the specific instance the second and third ducts differ in size from each other and from the size of the first duct from which they derive.

Also in this instance, in order to avoid air flow chokes and improve air conveyance in the second and third ducts, the extensions 21 A and 22A have the outer wall 21 B and 22B with a curved form ending over the edge of the bases 19A and 19B. Both bases 19A and 19B are connected to each other by means of six bottoms indicated with 19C, 19D, 19E, 19C\ 19D' and 19E\ respectively, for the side closure of the connector.

Also in this instance the edges of the bases 19A and 19B as well as of the extensions 21 A and 22A to be connected to the edges of the bottoms, have a 45° chamfer for coupling to a matching chamfer on the edges of the bottoms, and have them joining on a corner of the connector. Connection of the bottoms 19C, 19D, 19E, 19C, 19D' and 19E' to the bases 19B and extensions 21 A and 22A is made with adhesive agents. With reference to the Figures 5, 5A and 5B representing a view of a third connector type in a semi-finished form and final form according to the invention, reference 23 indicates a connector being apt to connect a main duct to a derived duct for air conveyance in environmental conditioning systems.

The connector 23 has a development 23' formed by a base 23A and two equal walls 23B perpendicular to the base 23A and connected to it by the aluminium coating foil of the panel from which the connector is obtained. The walls 23B, which have one a higher end than the other are joined together by a straight section 23C and inclined section 23D. The higher end is the one on the connector side to be connected to the main duct. Completion of the connector 23 will also require a second base 23D for the closure of the connector. Reference 24 indicates some 90° V-shaped notches for the 90° folding of the side walls 23B with respect to the base 23A (Figures 5A and 5B). Also in this case the edges of the base 23A to be connected to the edges of the second base 23D have a 45° chamfer for coupling to a matching chamfer on the edges of the second base 23D, so as to obtain a joint on a corner of the connector. Connection of the second base 23D to the side walls 23B is obtained by means of adhesive agents.

Back to Fig. 3A, execution of the connector 15 according to common art requires to draw the connector development and three bottoms on a panel P before the subsequent manual cutting of the profile and notches for side walls folding; in addition, also the 45° edges chamfer of the side walls to be connected to the matching 45° chamfered bottoms edges for the closure of the duct has to be executed manually. Moreover, the operator has to draw the development of both the connector and bottoms on the panel P in such a way to minimize machining scrap.

These operations are performed for each connector type and size to be executed; as a result, they require time and also involve a higher cost, as previously mentioned.

Execution of the connector 15 according to the present invention is based on the following procedure; the first input to furnish the following parameters in the electronic control system:

- type and dimensions of the connector to be executed for the electronic control system to define a most rational arrangement of the connector components on the panel P and minimize machining scrap;

- thickness of the panel P for the control system to define the distance between the motor-driven rollers 5 and idle rollers 6 for pulling off and/or pushing the panel during machining; then the machining stage for the execution of the connector and relevant components is enabled by the electronic control system for the following operations, i.e.:

- activating the motor-driven rollers 5;

- locating the carrier 7 for the tool 14 of the unit 12 to reach its start position for the machining operation, e.g. near a corner S of the connector to be executed;

- inserting the panel P between the first pair of rollers 5 and 6, for its dragging to the tool 14;

- activating rotation of the tool 14 and lowering the unit 12 for the end of the tool 14 to reach a position such to execute a through cut in the panel P; - feeding of the panel P activated by the electronic control system following the indication of the arrow F in Figure 3A for cutting the first plan section of the connector profile starting from the corner S; then the carrier 7 is also displaced following the path for executing the subsequent curved section with both combined movements; once the curved section has been executed, panel feed will stop and the carrier 7 alone is displaced for executing the horizontal plan section of the extension 17A; upon ending the horizontal plan section, the carrier 7 stops moving and the panel is fed for executing the edge plan section of the extension end 17A; once this execution has been performed, the panel P stops being fed and the carrier 7 is displaced inversely to the previous displacement for executing the second horizontal plan section of the extension 17A; now, also the horizontal feed of the panel P is activated inversely to the previous displacement for executing the semi-circular portion 17B of the extension 17A, and the feed of the panel P will stop while the carrier 7 keeps moving for executing the plan section at the end of the curve 17B; then the carrier 7 stops being fed and the panel P is displaced inversely to the previous displacement for executing the following plan section, then the carrier 7 is displaced inversely to the previous displacement for executing the subsequent inclined section; at the end of the inclined section the carrier 7 will stop while the panel P is further fed for executing the final section up to the corner S1 , where feeding of the panel P will also stop, since the profile cutting of a wall of the connector 15 has been performed,

- uplifting of the tool 14 for displacing it by means of the carrier 7 to the cutting start position of the profile of the second wall of the connector 15; during displacement of the carrier 7 the panel P is fed for positioning it with the corner S2 in line with the tool 14; - the procedure for cutting the profile of the second wall of the connector 15 is the same as previously described, but with reverse movements of the carrier 7;

- after cutting the profile of the second wall, the carrier 7 is positioned with the tool 13 in line with the location where the first notch 18 will be made;

- rotation of the tool 13 is activated and the unit 12 lowered for the tool 13 to meet the panel P and execute the notch 18; the depth of the notch 18 being such to reach the lower aluminium coating foil of the panel P without indenting it;

- feeding of the panel P is activated for enough time to execute the notch 18 all over the length of the connector 15;

- once the first notch 18 has been executed, the tool 13 is displaced to the position for performing the second notch 18; thereafter the procedure is the same as for executing the first notch;

- the tool 13 is positioned first on the corner S1 and then on the corner S2; a 45° chamfer is executed through the movements of the carrier 7 and panel P on the edge of the outer profile previously cut, as previously described; - the tool 13 is brought to its rest position and the tool 14 activated for cutting both the profile sides of the duct 15 delimiting its length, and detach it from the panel P.

It is obvious how execution of the second profile of the connector development 15 can be performed starting from the opposite corner instead of the corner S2 and proceed in the opposite direction to the cutting of the first profile.

After detaching the connector development 15, the bottoms 15C, 15D and 15E are made from the panel P in the same way as for the connector development 15, both for profile cutting and chamfer execution. Based on the size of the connector 15, several developments and bottoms can be made from the panel P up to its complete utilization.

Various operations for completing the connector 15 are performed on the connector development 15 and bottoms 15C, 15D and 15E exiting the apparatus 1 , i.e.:

- both side walls 15B are folded by 90° with respect to the base 15A by means of the notches 18, after inserting sealing material into the notch 18, e.g. adhesive, for preventing air leakage from inside to outside the connector 15,

- the bottoms 15C, 15D and 15E are appropriately shaped by means of common tools not described, according to the development profile they have to close,

- the same sealing and adhesive material is applied to the chamfered edges to be applied to the relevant duct sections to be closed.

The duct 15 is now executed and ready for use. Analogous operations are performed for executing the connectors represented in the Figures 4, 4A, 5, 5A and 5B.

From the above description also the advantages of an apparatus for executing air conveying duct connectors in environmental conditioning systems and of the connectors executed with said apparatus according to the present invention will become apparent. In particular they provide for:

- execution of the connector through a simple fast procedure;

- execution of the connector with advantageous time saving and consequent cost saving;

- automatic execution of the connector;

- best utilization of the polyurethane plate size for executing the connector;

- execution of connectors with varying outer and/or inner dimensions inserting their relevant dimensions in the electronic control system. It is clear that many other changes and applications can be easily used and made by the man skilled in the art to the apparatus for executing air conveying duct connectors in environmental conditioning systems as well as to the air conveying duct connectors in conditioning systems as described above by way of example.

By way of example, execution of a duct section for air conveyance to be connected to a duct with a minor section is represented in the Figures 6, 6A and

6B.

In Fig. 6 reference 25 indicates partially a section in its final execution form, whereas Fig. 6A illustrates the development of the tapered end of the section 25.

The section 25 consists of a base 25A and two equal walls 25B perpendicular to the base 25A and connected to it by the coating aluminium foil of the panel from which the section is obtained.

For completing the section 25 an upper bottom indicated with 25C is required for the closing wall of the section 25.

Reference 26 indicates some 90° V-shaped notches for the 90° folding of the side walls 25B with respect to the base 25A (Figs. 6A and 6B).

The edges of the walls 25B to be connected to the edges of the upper bottom 25C, have a 45° chamfer for their coupling to a matching chamfer on the bottom edge, for joining on one corner of the section.

Execution of the section 25 is performed according to the same procedures of the connector 15, i.e. through a combined panel-tools mutual movement in two orthogonal directions, minding to input both the form and size data of the section 25 in the electronic control system.

It is obvious that many other changes and applications can be easily used and made by the man skilled in the art to the apparatus for executing air conveying duct connectors in environmental conditioning systems as well as to the air conveying duct connectors for conditioning systems as described above by way of example, and it is also clear how in practical actuation of the present invention both the forms and dimensions of the components may differ from the ones described above and be replaced by technical equivalent elements.

* * * * *

Claims

1. An apparatus (1 ) for executing air conveying duct connectors (15;19;23) in environmental conditioning systems, comprising a basic structure (2), on which are at least provided:

- horizontal moving means (5,6) of an isolating panel (P), - cross traversing means (7,8,9,10,V,M) of a tool carrier (7), characterized in that, said horizontal motion means (5,6) and said cross traversing means (7,8,9,10,V,M) are activated individually and/or associated to each other for executing shaped components (15',15C,15D,15E;19A,19B,19C,19D,19E,19C, 19D',19E';23',23D;25S,25C) to obtain at least a connector (15;19;23) from said isolating panel (P).

2. An apparatus according to claim 1 , characterized in that said horizontal moving means (5,6) comprise at least a pair of rollers (5,6).

3. An apparatus according to claim 2, characterized in that said pair of rollers (5,6) comprises at least a motor-driven roller (5).

4. An apparatus according to claim 3, characterized in that said motor- driven roller (5) is apt to rotate in both directions for the motion of said panel (P).

5. An apparatus according to claim 1 , characterized in that said cross traversing means (7,8,9,10,V,M) comprise a carrier (7), being apt for a transverse traverse in both senses.

6. An apparatus according to claim 5, characterized in that said carrier (7) comprises at least a first (11 ) and second work unit (12), being apt for an upright movement.

7. An apparatus according to claim 5, characterized in that said first work unit (11 ) comprises a tool (13) on one end, being apt for material removal.

8. An apparatus according to claim 5, characterized in that said second work unit (12) comprises a tool (14) on one end, being apt for cutting.

9. An apparatus according to claim 8, characterized in that said tool (14) comprises a cylindrical milling cutter (14), being apt for executing the development of said connector (15; 19;23).

10. An apparatus according to claim 7, characterized in that said tool (13) comprises a coned milling cutter (13), being apt for executing notches (18;22;26) and chamfering the edges of the development of said connector (15;19;23).

11. An apparatus according to claim 5, characterized in that said transverse traverse of said carrier (7) is performed by means of a screw (V) controlled by an electric motor, in particular a direct current motor.

12. An apparatus according to claim 11 , characterized in that said screw (V) is associated to a nut screw (M) solidly connected to said carrier (7).

13. An apparatus according to claim 1 , characterized in that all operations of said apparatus (1 ) for executing said connector (15;19;23) are controlled and managed by an electronic control system.

14. A method for executing air conveying duct connectors (15;19;23) in environmental conditioning systems using an apparatus according to one or more of the previous claims.

15. A method according to the previous claim, characterized in that it comprises a first data input stage in said electronic control system, a second execution stage of the shaped components of said connector (15',15C,15D,15E;19A,19B,19C,19D,19E,19C',19D',19E';23',23D;25S,25C) and a third execution stage of said connector (15;19;23).

16. A method according to the previous claim, characterized in that during said first stage the following data are inserted in the electronic control system:

- type and dimensions of the connector (15;19;23) to be executed,

- thickness of the panel (P), from which the connector has to be made (15;19;23).

17. A method according to claim 14, characterized in that said second execution stage of the shaped components (15',15C,15D,15E;19A,19B,19C,19D, 19E,19C',19D',19E';23',23D;25S,25C) of said connector (15;19;23) comprises:

- activating the motor-driven rollers (5),

- locating the carrier (7) for the tool (14) of said second unit (12) to be in the starting position for executing one side of a shaped component (15',15C, 15D,

15E;19A,19B,19C,19D,19E,19C',19D',19E';23',23D;25S,25C) of said connector (15; 19;23),

- inserting the panel (P) between the first pair of rollers (5,6), which provide for its dragging to said tool (14) of said second work unit (12),

- activating rotation of said tool (14) and lowering the second unit (12) to bring said tool (14) in position for executing a through cut in the panel (P),

- feeding and/or backing the panel (P) by means of the pairs of rollers (5,6),

- activating and/or deactivating the transverse movement in one or the other direction of said carrier (7),

- positioning said tool (14) at the starting location for profile cutting of the second development side of said connector (15; 19;23),

- feeding and/or backing the panel (P) by means of the pairs of rollers (5,6),

- activating and/or deactivating the transverse movement in one or the other direction of said carrier (7).

18. A method according to claim 17, characterized in that it further comprises:

- locating the tool (13) of said first work unit (11 ) in line with the starting location for executing a first notch (18;22;26),

- activating rotation of the tool (13) and lowering the second work unit (12),

- activating the feed of the panel (P) for enough time for executing said first notch (18;22;26),

- executing a second notch (18;22;26) parallel to said first notch (18;22;26),

- locating the tool (13) on the profile of a first development side for executing a chamfer on the profile edge,

- locating the tool (13) on the profile of the second development side for executing a chamfer on the profile edge,

- activating the tool (14) of said second work unit (12) for cutting the third side and subsequently the fourth side for the detachment of the panel (P).

19. A method according to claim 15, characterized in that said third execution stage of said duct (15;19;23) comprises: - sealing of said notches (18;22),

- folding of the sides (15B,23B) by means of said notches (18;22), - shaping of the components (15C,15D,15E;23D),

- assembly of the components (15C,15D,15E;23D) by means of adhesive material.

20. A method according to claim 18, characterized in that said notches (18;22;26) have a depth such to reach a lower aluminium coating foil of said panel

(P) without indenting it.

21. A method according to claim 16, characterized in that said electronic control system defines the arrangement of the components (15',15C,15D, 15E;19A,19B,19C₁19D_I19E,19CM9DM9E^,;23^,,23D;25S_I25C) of the connector (15;19;23) on the panel (P), so as to minimize machining scrap.

22. A connector (15;19;23) for air conveying ducts in environmental conditioning systems, executed with the apparatus and/or method according to the previous claims.