U.S. patent application number 10/067726 was filed with the patent office on 2002-09-12 for flanged connector for hvac ducting.
Invention is credited to Hermanson, Jeffrey A..
Application Number | 20020124614 10/067726 |
Document ID | / |
Family ID | 27540494 |
Filed Date | 2002-09-12 |
United States Patent
Application |
20020124614 |
Kind Code |
A1 |
Hermanson, Jeffrey A. |
September 12, 2002 |
Flanged connector for HVAC ducting
Abstract
A method of making circular and oval flanged rings, for the
connection of thin, double walled circular and oval ducting, from
10 to 20 gauge steel. The steel is cut into strips with the strip
ends butt welded forming flanged ring band stock which is inserted
5 and clamped into a spinning die. The spinning die is rotated
while machine tools are used to form the flanged ring band stock
into a first circular flanged ring. A second flanged ring band
stock is manufactured using substantially the same method as above.
The two formed rings are attached to form a single flanged
ring.
Inventors: |
Hermanson, Jeffrey A.;
(Sumner, WA) |
Correspondence
Address: |
CHRISTENSEN, O'CONNOR, JOHNSON, KINDNESS, PLLC
1420 FIFTH AVENUE
SUITE 2800
SEATTLE
WA
98101-2347
US
|
Family ID: |
27540494 |
Appl. No.: |
10/067726 |
Filed: |
February 4, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10067726 |
Feb 4, 2002 |
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09956745 |
Sep 17, 2001 |
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10067726 |
Feb 4, 2002 |
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09484741 |
Jan 18, 2000 |
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6289706 |
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10067726 |
Feb 4, 2002 |
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09441037 |
Nov 16, 1999 |
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6301781 |
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10067726 |
Feb 4, 2002 |
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08616655 |
Mar 15, 1996 |
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5983496 |
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60266087 |
Feb 2, 2001 |
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Current U.S.
Class: |
72/82 |
Current CPC
Class: |
B21D 19/00 20130101;
B21D 53/16 20130101; F24F 13/0209 20130101; B21D 22/16
20130101 |
Class at
Publication: |
72/82 |
International
Class: |
B21D 022/14 |
Claims
The embodiments of the invention in which an exclusive property or
privilege is claimed are defined as follows:
1. A flanged ring used as a connector to join double wall ducts in
HVAC systems, the double wall ducts having an outer duct and an
inner duct disposed within the outer duct, the flanged ring
comprising: a first generally cylindrical-shaped ring composed of
from 10-20 gauge metallic material, said first ring having a cross
section with an outer insertion flange, said outer insertion flange
having sufficient length to allow connection to an outer duct of a
double wall duct; an exterior mating flange extending substantially
transversely from the outer insertion flange to define a first
mating face and a first outer perimeter; an exterior hem that is
substantially concentric to the outer insertion flange, said
exterior hem extending outwardly from the outer perimeter of the
exterior mating flange; a second generally cylindrical-shaped ring
composed of from 10-20 gauge metallic material, said second ring
having a cross section with an inner insertion flange, said inner
insertion flange having sufficient length to allow connection to an
inner duct of a double wall duct; an interior mating flange
extending substantially transversely from the inner insertion
flange to define a second mating face and a second outer perimeter;
and an interior hem that is substantially concentric to the inner
insertion flange, said interior hem extending from the outer
perimeter of the interior mating flange generally in the same
direction as the inner insertion flange to overlap the outer
insertion flange wherein the interior hem is connected to the outer
insertion flange by any common means of fastening such that the
interior mating flange and the exterior mating flange are aligned
to form substantially one plane, the connection hem being of such
length to permit the outer insertion flange to be connected to the
interior of the outer duct wall and having sufficient length to
allow connection with the outer insertion flange.
2. The flange ring in claim 1, wherein the inner insertion flange
is longer than the outer insertion flange.
3. The flange ring in claim 1, wherein the interior hem is fixably
attached to the outer insertion flange.
4. The flange ring in claim 1, wherein the outer and inner
insertion flanges slidably engages inside surfaces of the outer and
inner ducts.
5. The flange ring in claim 1, further comprising a return flange
affixed to the exterior hem, formed by turning a portion of the
exterior hem located distally from the exterior mating flange over
on itself.
6. The flange ring in claim 5, wherein the profile of the flange
ring conforms to Sheet Metal and Air-Conditioning Contractors
National Association Standard T24.
7. The flange ring in claim 1, wherein the outer insertion flange
is welded to the interior hem.
8. A flanged ring used as a connector to join double wall ducts in
HVAC systems, the double wall ducts having an outer duct and an
inner duct disposed within the outer duct, the flanged ring
comprising: an oval-shaped ring composed of from 10-20 gauge
metallic material, said first ring having a cross section with an
outer insertion flange, said outer insertion flange having
sufficient length to allow connection to an outer duct of a double
wall duct; an exterior mating flange extending substantially
transversely from the outer insertion flange to define a first
mating face and a first outer perimeter; an exterior hem that is
substantially concentric to the outer insertion flange, said
exterior hem extending outwardly from the outer perimeter of the
exterior mating flange; a second cylindrical-shaped ring composed
of from 10-20 gauge metallic material, said second ring having a
cross section with an inner insertion flange, said inner insertion
flange having sufficient length to allow connection to an inner
duct of a double wall duct; an interior mating flange extending
substantially transversely from the inner insertion flange to
define a second mating face and a second outer perimeter; and an
interior hem that is substantially concentric to the inner
insertion flange, said interior hem extending from the outer
perimeter of the interior mating flange generally in the same
direction as the inner insertion flange to overlap the outer
insertion flange wherein the interior hem is connected to the outer
insertion flange by any common means of fastening such that the
interior mating flange and the exterior mating flange are aligned
to form substantially one plane, the connection hem being of such
length to permit the outer insertion flange to be connected to the
interior of the outer duct wall and having sufficient length to
allow connection with the outer insertion flange.
9. The flange ring in claim 8, further comprising a return flange
structurally integral with the exterior hem, said return flange
formed by forming a portion of the exterior hem located distally
from the exterior mating flange over on itself.
10. The flange ring in claim 8, wherein the outer insertion flange
is welded to the interior hem.
11. A method of spin forming a flanged ring used as a connector to
join double wall ducts in HVAC systems, the double wall ducts
having an outer duct and an inner duct disposed within the outer
duct, the method comprising: (a) spinning a cylindrical,
collar-shaped workpiece composed of from 10 gauge or greater
metallic material locked into a spin die about its central axis,
the spin die having an annular shaped end edge, the workpiece
having a first end portion extending beyond the edge of the spin
die and outer diameter substantially equal to the inner diameter of
outer duct to be connected; (b) forming the first end portion of
the workpiece as the workpiece is spinning to expand the workpiece
against the end edge of spin die to define a generally annular
shaped exterior mating flange extending substantially transversely
to the remainder of the original workpiece to define an outer
perimeter, the remainder of the original workpiece retaining its
original diameter to form an outer insertion flange; (c) further
forming the locked workpiece while the locked workpiece is spinning
to form an exterior hem, the hem extending outwardly from the
exterior mating flange; (d) spinning a second cylindrical,
collar-shaped workpiece composed of from 10 gauge or greater
metallic material locked into a spin die about its central axis,
the spin die having an annular shaped end edge, the workpiece
having a first end portion extending beyond the edge of the spin
die and outer diameter substantially equal to the inner diameter of
inner duct to be connected; (e) forming the first end portion of
the workpiece as the workpiece is spinning to expand the workpiece
against the end edge of spin die to define a generally annular
shaped interior mating flange extending generally transversely to
the remainder of the original workpiece to define an outer
perimeter, the remainder of the original workpiece retaining its
original diameter to form an inner insertion flange; (f) further
forming the locked workpiece against the spin die while it is
spinning to form an interior hem, the hem extending transversely
from the interior mating flange in the same direction as the inner
insertion flange; and (g) connecting the first collar-shaped
workpiece to the second collar-shaped workpiece by any common means
of fastening such that the exterior mating flange and the interior
mating flange are aligned to form substantially one plane.
12. The method according to claim 11, further comprising forming a
return flange by applying a forming tool to the distal edge of the
exterior hem so as to turn a portion of the hem over on itself.
13. The method according to claim 11, further comprising welding
the outer insertion flange to the interior hem such that the
exterior and interior mating flanges are aligned to substantially
form one plane.
14. The method according to claim 12, wherein the profile of the
flange ring conforms to Sheet Metal and Air-Conditioning
Contractors National Association Standard T24.
15. The method according to claim 11, further comprising locking
each workpiece to the inside diameter the spin die prior to forming
the mating flanges.
16. The method according to claim 11, further comprising: (a)
placing each cylindrical collar-shaped workpiece in a spin die
having an inner diameter that substantially corresponds to the
desired diameter of each of the insertion flanges; (b) locking each
workpiece to the inner diameter of the spin die; and (c) spinning
the workpiece by spinning the spin die.
17. The method according to claim 11, wherein: (a) the exterior hem
and the interior hem are formed having a proximal edge portion and
a distal edge portion, for subsequent attachment to the outer
perimeter of the exterior mating flange and the interior mating
flange, respectively, so that the hem sections extend outwardly
from the outer perimeter of each mating flange substantially
concentrically to the both the outer and inner insertion flanges;
and (b) the proximal edge portion of the hem sections are attached
to the outer perimeter of the mating flanges to form a
substantially air tight connection therebetween.
18. The method according to claim 11, wherein an oval-shaped flange
ring is formed to connect sections of oval double wall ducts
comprising: (a) diametrically cutting the completed flange ring
formed by the method in claim 1 into two generally semi-circular
ring halves; (b) inserting straight flanged sections between the
corresponding ends of said semi-circular ring halves to form a
generally oval-shaped ring, said straight flange sections to have
substantially the same cross section as the cross section of the
semicircular ring halves; and (c) affixing the corresponding ends
of the straight flange sections to the corresponding ends of the
semi-circular ring halves to form a single oval-shaped flange
ring.
19. A method of spin forming a flanged ring used as a connector to
join double wall ducts in HVAC systems, the double wall ducts
having an outer duct and an inner duct disposed within the outer
duct, the method comprising: (a) forming a generally
annularly-shaped exterior mating flange extending transversely to
the central axis of the ducting to be interconnected, the mating
flange defining a circular central opening and a circular outer
perimeter; (b) forming the outer perimeter of the transverse mating
flange to form an exterior hem disposed substantially
concentrically to the central opening of the exterior mating
flange; (c) attaching the exterior mating flange at its central
opening to a generally cylindrical outer insertion flange so that
the insertion flange projects generally transversely from the
exterior mating flange, the insertion flange sized to closely fit
within the section end of outer ducting to be connected; (d)
forming a second generally annularly-shaped interior mating flange
extending transversely to the central axis of the ducting to be
interconnected, the mating flange defining a circular central
opening and a circular outer perimeter; (e) forming the outer
perimeter of the transverse mating flange to form an interior hem
disposed substantially concentrically to the central opening of the
interior mating flange; (f) attaching the interior mating flange at
its central opening to a generally cylindrical inner insertion
flange so that the insertion flange projects generally transversely
from the interior mating flange, the insertion flange sized to
closely fit within the section end of outer ducting to be
connected; and (g) Attaching the outer insertion flange to the
interior hem so that the exterior mating flange and the interior
mating flange are aligned to form substantially one plane.
20. The method according to claim 19, further comprising forming an
exterior return flange portion by turning a portion of the exterior
hem section located distally from the exterior mating flange over
on itself.
Description
CROSS-REFERENCES TO RELATED APPLICATION(S)
[0001] This application claims the benefit from U.S. provisional
patent application serial No. 60/266,087, the disclosure of which
is hereby expressly incorporated by reference. This application is
also a continuation-in-part of U.S. application Ser. No.
09/956,745, filed Sep. 17, 2001, which is a continuation of U.S.
application Ser. No. 09/484,741, filed Jan. 18, 2000, and now U.S.
Pat. No. 6,289,706, which is a continuation-in-part of U.S.
application Ser. No. 09/441,037 filed Nov. 16, 1999, and now U.S.
Pat. No. 6,301,781, which is a continuation-in-part of U.S.
application Ser. No. 08/616,655, filed Mar. 15, 1996 and now U.S.
Pat. No. 5,983,496.
FIELD OF THE INVENTION
[0002] The present invention relates to circular and oval flanged
rings for connecting double wall circular and oval heating,
ventilation and air conditioning (HVAC) ducting sections, from thin
gauge lock form quality steel, and a method for spin-forming such
flanged rings.
BACKGROUND OF THE INVENTION
[0003] Joint assemblies are well known for the connection of the
ends of adjacent rectangular, circular, and oval HVAC duct
sections. U.S. Pat. No. 5,129,690 to Meinig recites prior art
relating to such assemblies and discloses an apparatus for
connecting the ends of oval duct sections without disclosure of the
method of making the apparatus; the patent does refer to U.S. Pat.
No. 4,516,797 to Meinig which discloses a one-piece flanged ring
for connecting the ends of circular duct sections. U.S. Pat. No.
4,516,797 discloses a method for producing the flanged ring by
contouring and then bending an elongated sheet-metal strip into an
annular shape resulting in a flanged ring having an axial slit and
claiming a method for producing a flanged ring characterized as an
elongated sheet metal strip which is contoured and subsequently
bent into annular form.
[0004] The machine method used to produce such a flanged ring is
known to include roll forming. However, roll forming is limited
generally to sheet-metal less than 10 gauge with roll forming
causing tearing or breaking of sheet-metal in the production of
flanged rings from thinner sheet-metal of gauge 10 or greater.
Circular flanged rings, produced by roll forming, and thin-walled
sheet-metal ducting generally do not have an absolutely circular
cross section. The predominant means of manufacturing HVAC ducting
is in the form of spiral seam tubes made up of helical wound
sheet-metal strips with the strips interconnected by means of lock
seams. The lock seams stand out from the outer duct face.
[0005] U.S. Pat. No. 4,516,797 and U.S. Pat. No. 5,129,690 to
Meinig are identified and disclosed in accordance with 37 C.F.R.
.sctn.1.97.
SUMMARY OF THE INVENTION
[0006] Objects of this invention are double wall circular and oval
flanged rings from Lock Form Quality steel of gauge 10 to 20, for
the connection of the ends of thin-, double-walled circular and
oval sheet-metal tubes or ducting and how to make them by spinning,
forming, and trimming, with standard machine tools and machining
processes. The present invention is capable of making Flanged Rings
that comply to the T24 flange profile and other profiles of the
Sheet Metal and Air-Conditioning Contractors National Association
(SMACNA). The method includes LFQ steel strips that may be rolled
into flanged ring band stock strips having strip first and second
ends which are butt welded together with a tungsten inert gas
process with no filler. A spinning die, which is balanced and which
has structural means or supporting structural member means,
receives the flanged ring band stock which may be secured within
the spinning die by appropriate means, for example by clamp means.
The spinning die is rotated by means, for example by a lathe, and
machine tools are employed to stretch, form and trim the flanged
ring band stock to produce a first circular flanged ring. A second
circular flanged ring may be produced by the same method in a
second spinning die and then attached to the first circular flanged
ring to form one double-wall circular or oval flanged ring for the
connection of circular and oval thin gauged double-wall pipe or
ducting sections.
[0007] One preferred embodiment of the flanged ring profile
described herein constitutes the Sheet Metal and Air-Conditioning
Contractors National Association (SMACNA) standard T24 Flange
Profile. The profile disclosed is not limited to the SMACNA T24
profile. However, the method disclosed produces circular or oval
flanged rings while the SMACNA T24 Flange Profile refers solely to
flanges for the connection of rectangular ducting sections. This
disclosure is the only known method of producing the SMACNA T24
Flange Profile for circular and oval flanged rings from 10 or
greater gauge LFQ steel. The SMACNA T24 Flange Profile or cross
section produced by the method described has an outer insertion
flange portion which is secured within the spinning die by means
including clamp means, an exterior mating flange portion which is
stretched and formed and which meets and matches an opposing mating
flange portion, an exterior hem portion which is formed, and a
return flange, and an inner insertion flange portion which is
secured within the second spinning die by means including clamp
means, an interior mating flange portion which is stretched and
formed and which meets and matches an opposing mating flange
portion, and an interior hem portion which is formed.
[0008] The oval double-wall flanged ring is produced by cutting a
circular, double-wall flanged ring along a diameter to produce
approximately equal sized semi-circular flange ring portions. Equal
length SMACNA T24 Linear Segments of the SMACNA T24 Flange Profile
are produced, for instance by roll forming, and are welded to the
semicircular flanged ring portions to produce the oval flanged
ring.
[0009] One preferred embodiment of the present disclosed method
results in the production of the SMACNA T24 Flange Profile from 10
to 20 gauge Lock Form Quality steel (under 30,000 psi
yield/tensile, galvanized G60; however, any metal which can be
turned in the following described process and which can be welded
may be used for production). The preferred embodiment of the
described method requires the preparation of flanged ring band
stock from 3.87511 wide 10 to 20 gauge LFQ steel. The material and
material width may be varied as preferred.
[0010] An additional object of this invention is the formation of a
circular, double-wall flanged ring which is more nearly circular in
cross section than double-wall flanges produced by other means. The
truer circular cross section facilitates the insertion of the
circular flanged ring in the spiral-seam tubes comprising most
circular and oval HVAC ducting. The method disclosed of making the
circular double-wall flanged ring enables the use of much thinner
gauge steel for the connection of duct section ends and in creating
an airtight connection between duct section ends. The circular
double-wall flanged ring, produced by a spinning process, is more
uniformly circular in cross section than are flanges produced from
a roll forming or press operation and more readily sealed, without
elaborate gaskets.
[0011] In a further aspect of the present invention, the flange
rings of the double-wall construction may be made in a two-step
process with the mating flange portions being spin formed. The hem
sections and/or the return flange are separately formed and then
butt-welded or otherwise attached to the outer perimeter of the
mating flanges. In another aspect of the present invention, the
flanged rings can be manufactured by forming the insertion flanges
as a singular component and then forming the mating flanges, hem
sections and/or return flange as the second component, perhaps by
roll forming or stamping. The two components can be assembled by
welding the inside perimeter of the mating flanges to the end edge
of the insertion flanges.
[0012] As a further aspect of the present invention, the flanged
rings can be manufactured by spin forming the mating flanges in the
manner described above. Thereafter, the hem sections can be formed
by a roll forming method using roll forming dies. If a return
flange is utilized, the hem section and return flange can both be
formed from the material stock extending beyond the outer perimeter
of the mating flanges, through the use of a series of roller
sets.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The foregoing aspects and many of the attendant advantages
of this invention will become more readily appreciated as the same
become better understood by reference to the following detailed
description, when taken in conjunction with the accompanying
drawings, wherein:
[0014] FIG. 1 is an elevational view of the Circular Flanged
Ring.
[0015] FIG. 1A is a section of FIG. 1 showing the cross section or
profile of a T24 SMACNA Circular Flanged Ring and effectively the
elevation view representative of both Circular and Oval Flanged
Rings.
[0016] FIG. 2 is a detail showing a cross section of the
interrelationship of the Circular Flanged Ring inserted into
ducting, of the Mating Flanges of opposing Circular Flanged Rings
meeting in preparation for connection with Sealant depicted between
the Mating Flanges.
[0017] FIG. 3 depicts circular Flanged Rings, inserted into
ducting, of the Mating Flanges of opposing Circular Flanged Rings
meeting in preparation for connection.
[0018] FIG. 4 is a detailed cross section depicting the connection
of the Circular Flanged Ring from insertion flange to ducting and
between Mating Flanges by screw means where Sealant is spread
between the Mating Flanges.
[0019] FIG. 5 is an elevational view of a Circular Flanged Ring, as
depicted in FIGS. 1 and 3, cut along a common diameter in
preparation for insertion of SMACNA T24 Linear Segments with the
T24 cross section as a step in producing the T24 cross section Oval
Flanged Ring.
[0020] FIG. 5A is a plan view of an assembled Oval Flanged Ring
depicting the connection of the Semicircular Flanged Ring Portions
to the SMACNA T24 Linear Segments by means of welding.
[0021] FIG. 6 is an exploded side view of a Lathe Output Shaft with
attached Adapter Plate, Backing Plate and Spinning Die.
[0022] FIG. 7 is an elevation view of the Adapter Plate Reverse
Side.
[0023] FIG. 7A is an elevation view of the Adapter Plate Obverse
Side.
[0024] FIG. 8 is an elevation view of the Backing Plate Reverse
Side.
[0025] FIG. 8A is an elevation view of the Backing Plate Obverse
Side.
[0026] FIG. 9 is an elevation view of the Mounting Surface of a
Spinning Die.
[0027] FIG. 9A is an elevation view of the Working Surface of a
Spinning Die showing the Collar, clamp means and threaded means for
mounting purposes.
[0028] FIG. 9B is a perspective view of the Spinning Die.
[0029] FIG. 10 is a perspective view of a Flanged Ring Band Stock
Strip of LFQ steel cut to length in preparation for rolling into a
band or circular form.
[0030] FIG. 10A is a perspective view of a rolled strip of LFQ
steel formed into a band shape with Strip First and Second Ends
ready to be butt welded together.
[0031] FIG. 10B is a perspective view of a Flanged Ring Band Stock
which has been butt welded and is ready for insertion into a
Spinning Die in preparation for spinning, stretching, forming and
trimming into a Circular or Oval Flanged Ring.
[0032] FIG. 11 is a perspective showing the Flanged Ring Band Stock
and the Spinning Die.
[0033] FIG. 11A is a side view of a Flanged Ring Band Stock
prepared to be inserted and secured in a Spinning Die.
[0034] FIG. 11B is a side view of a Flanged Ring Band Stock in the
inserted position within a Spinning Die in preparation for
machining steps directed to the production of a Circular Flanged
Ring.
[0035] FIG. 11C is a detail view showing a portion of the Spinning
Die including the Collar and Collar components (Collar Strip and
Mating Strip), a Flanged Ring Band Stock received by the Collar and
into the Working Surface Groove and secured by a Cam Clamp.
[0036] FIG. 12 is a depiction of an Internal Roller machine tool
with the Internal Roller Wheel having ideally about a 1/2" radius
configured at 90 degrees to an axis through the Internal Roller
Handle First to Second End.
[0037] FIG. 13 is a depiction of a Radius Roller with the Radius
Roller Wheel having ideally about a 1/8" radius configured in line
with an axis through the Radius Roller Handle First to Second
End.
[0038] FIG. 14 is a depiction of a Finishing Roller with the
Finishing Roller Wheel having ideally about a 1/2" radius
configured in line with an axis through the Finishing Roller Handle
First to Second End.
[0039] FIG. 15 is a depiction of a Trim Lever which provides
ideally about a 1/2" square.times.31/2" carbide insert Cutting Tip
configured in line with an axis through the Trim Lever Handle First
to Second End.
[0040] FIG. 16 is a side view of a Power Lever from which all other
machine tools employed herein are operated to obtain leverage for
the stretching, forming and trimming operations. Top Surface and
Bottom Surface Pins are depicted.
[0041] FIG. 16A is a plan view showing the Power Lever Head and
Power Lever Top Surface Pin.
[0042] FIG. 16B is a bottom view showing the Power Lever Head and
Power Lever Bottom Surface Pin.
[0043] FIG. 17 is a plan view showing a Tool Rest which is affixed
to a lathe cradle. The Tool Rest has a plurality of apertures which
receive the Power Lever Bottom Surface Pin for positioning and
working the machine tools in stretching, forming and trimming the
Circular Flanged Ring.
[0044] FIG. 17A is a perspective showing the Tool Rest Top and a
plurality of apertures which will receive the Power Lever Bottom
Surface Pin.
[0045] FIG. 18 is a partial cross sectional view showing the
Flanged Ring Band Stock inserted into a Spinning Die in preparation
for the machining steps to produce a Circular Flanged Ring.
[0046] FIG. 18A is a partial cross-sectional view showing the
results of the first machining step which is to stretch the portion
of the Flanged Ring Band Stock which protrudes from the Spinning
Die into a Mating Flange.
[0047] FIG. 18B is a partial cross-sectional view showing the
association of the Follow Block with the Mating Flange and the
forming of the Hem.
[0048] FIG. 18C is a partial cross-sectional view showing the final
step consisting of forming the Return Flange of the Circular
Flanged Ring.
[0049] FIG. 19 is a plan view of a Follow Block comprised of
Circular Cut Plywood Pieces 3/4" thick positioned concentrically
with a 1" thick.times.6" diameter mild steel Tail Stock Plate
having a centrally located Tail Stock Aperture.
[0050] FIG. 19A is an elevation of a Follow Block.
[0051] FIG. 20 is an elevation of the assembly restraining the
Flanged Ring Band Stock including the Lathe Output Shaft, the
Adapter Plate, the Spinning Die, the Flanged Ring Stock, and the
Follow Block;
[0052] FIG. 21 is a view similar to FIG. 2 showing another
embodiment of the present invention;
[0053] FIG. 22 is a view similar to FIG. 21 showing a further
embodiment of the present invention;
[0054] FIGS. 23A, 23B, 23C, 23D, 23E, and 23F illustrate another
method of forming the present invention; and
[0055] FIGS. 24A, 24B, and 24C, and 24D illustrate a further method
of forming the present invention.
[0056] FIG. 25 is a further embodiment of the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0057] While the preferred embodiment of the invention has been
illustrated and described, it will be appreciated that various
changes can be made therein without departing from the spirit and
scope of the invention.
[0058] The preferred embodiment, shown in FIG. 25, of the flanged
ring profile 501 consists of a first cylindrical flanged ring 511
and a second cylindrical flanged ring 512 fastened together to form
a single flange ring profile 501. The fastening means may consist
of, but is not limited to, a welding means. A circular or oval
flange ring 510 or 520 is attached to the double wall duct 532 in
two locations.
[0059] The flange ring profile 501 is created by the joining of a
first cylindrical flanged ring 511 and a second cylindrical flanged
ring 512. The first cylindrical flanged ring 511 is composed of 10
gauge or greater metallic material. The first cylindrical flanged
ring 511 has a cross section consisting of the following:
[0060] 1) An outer insertion flange 503 that is of sufficient
length to connect to the outer wall 530 of a double wall duct
532.
[0061] 2) An exterior mating flange 504 that extends approximately
90.degree. from the outer insertion flange 503. The exterior mating
flange 504 defines a first mating face 507 that contacts the seal
508 when circular or oval flanged ring connectors 510, 520 are
opposing each other and connecting two sections of double wall duct
532.
[0062] 3) An exterior hem 505 that extends outwardly from, and is
approximately concentric with, the outer mating flange 504. The
exterior hem 505 may extend from the exterior mating flange 504 in
generally the same direction as the outer insertion flange 503. Of
course, the hem 505 need not define a cylindrical shape.
[0063] 4) An optional return hem 506 may be formed by folding a
portion of the exterior hem 505 located distally from the exterior
mating flange 504 over upon itself. The return hem 509 may be
substantially flattened against exterior hem 505 or may be in other
configurations. Also, the exterior hem 505 and return hem 506 may
together define various cross-sectional shapes such as round, oval,
elliptical, etc., and thus may have a hollow interior. Rather than
being hollow, the interior defined by the round, oval, or
elliptical cross section may be filed with a circular-shaped rod or
ring member for additional strength.
[0064] The second cylindrical flanged ring 512 is composed of 10
gauge or greater metallic material. The second cylindrical flanged
ring 512 has a cross section consisting of the following:
[0065] 1) An inner insertion flange 513 that is of sufficient
length to connect to the inner wall 531 of a double wall duct
532.
[0066] 2) An interior mating flange 514 that extends approximately
90.degree. from the inner insertion flange 513. The interior mating
flange 514 defines a second mating face 517 that contacts the seal
508 when circular or oval flanged ring connectors 510, 520 are
opposing each other and connecting two sections of double wall duct
532.
[0067] 3) An interior hem 515 that is approximately concentric with
the inner mating flange 513. The interior hem 515 extends from the
interior mating flange 514 in the same direction as the inner
insertion flange 513. The interior hem 515 extends from the
interior mating face a sufficient distance to allow connection with
the first cylindrical flanged ring 511 yet not to interfere with
the connection of the outer insertion flange 503 and the outer wall
530 of a double wall duct 532.
[0068] The flanged ring profile 501 is completed when the first
cylindrical flanged ring 511 is fastened to the second cylindrical
flanged ring 512. The first cylindrical flanged ring 511 is aligned
with the second cylindrical flanged ring 512 so that the exterior
mating flange 504 and the interior mating flange 514 form one
plane. The connection may by accomplished by welding, but is not
limited to that method of fastening. Two sections of double wall
duct may now be connected. The outer insertion flange 503 is
attached to the inner diameter of the outer wall 530 of the double
wall duct 532. The inner insertion flange 513 is attached to the
inner diameter of the inner wall 531 of the double wall duct 532.
Two opposing circular or oval flange rings 510, 511 are attached
with a seal 508 being trapped between the first and second mating
surfaces 507, 517.
[0069] One preferred embodiment of making the disclosed Circular
Flanged Rings 510, 512 includes the following materials, steps and
process: LFQ steel, or other Flanged Ring Band Stock 40 material,
is normally received in coil form and is decoiled and cut into
Flanged Ring Band Stock Strips 41 having Strip First and Second
Ends 44, 46, as shown in FIG. 10, the length of the circumference
of the Circular Flanged Rings 510, 512 to be produced (Flanged Ring
Band Stock Strips 41 of widths other than 3.875" may also be used
with the width limited by the configuration of the Spinning Die 50
and the dimensions of the desired Circular Flanged Rings 510, 512).
Each Flanged Ring Band Stock Strip 41 is formed into a band form,
which is substantially circular as shown in FIG. 10A, for ease of
affixing the Strip First and Second Ends 44, 46 together, for
example, by butt welding the Strip First and Second Ends 44, 46
together, with the band forming accomplished by means, for example,
with a rolling machine including a pyramid rolling machine. The
preferred means of connection of the Strip First and Second Ends
44, 46 is by butt welding by use of a tungsten inert gas process
with no filler. The butt welding forms the Strip First and Second
End Weld 48 and concludes the formation of the Flanged Ring Band
Stock 40 as shown in FIG. 10B. It is important, for successful
spinning and forming of the Circular Flanged Rings 510, 512, that
the butt weld of the Strip First and Second Ends 44, 46 not produce
a seam. Any seam, ridge, irregularity or any fill in the weld will
increase the probability of the seam cracking, as the Flanged Ring
Band Stock 40 is stretched in the spinning process, ruining the
Flanged Ring Band Stock 40 and creating a safety hazard. The
Flanged Ring Band Stock 40 will be received within and secured into
a Spinning Die 60 as shown in FIGS. 10, 10A and 10B.
[0070] The disclosed process requires two workpieces of Flanged
Ring Band Stock 40 to be rotated or spun for forming and trimming
and then fastened together. Each Flanged Ring Band Stock 40 may be
fixed in a die which is in turn rotated or spun for presentation to
and work by various machine tools. The rotation of the die means
and Flanged Ring Band Stock 40 may be accomplished, for example, by
a lathe with either a vertically or a horizontally mounted Lathe
Output Shaft 50. The preferred embodiment, for example, utilizes a
lathe with a horizontally mounted Lathe Output Shaft 50 to which is
mounted, via adapter and/or mounting means, a Spinning Die 60.
[0071] The die means may be provided, for example by a Spinning Die
60 shown in FIGS. 9, 9A, and 9B, which in the preferred embodiment,
may consist of a circular Base Plate 61 formed from approximately
1" thick mild steel plate having a Mounting Surface 62 and a
Working Surface 64 and an outside diameter approximately 1" greater
than the outside diameter of the Flanged Ring Band Stock 40 which
is selected for forming and trimming. Mounting means may be
provided which enable the Lathe Output Shaft 50 to be located at
the effective center of the Mounting Surface 62. On the Working
Surface 64 of the Base Plate 61, a die means or fixture receives
and secures the Flanged Ring Band Stock 40 and may be provided, for
example, by a Collar 70 assembled from components consisting of: 1)
a Collar Strip 72 consisting of 3/8" thick.times.2" wide mild steel
strip which is rolled to a 2" wide strip in a circular form having
an inside diameter approximately {fraction (1/16)}" greater than
the outside diameter of the Flanged Ring Band Stock 40 and with the
strip width of approximately 2". The Collar Strip 72 has End Edges
73, 74. The End Edge 74 may be tack-welded to the Working Surface
64 of the Base Plate 61 so that the Collar 70 and Spinning Die 60
are concentric around the center of the Spinning Die 60. The
interior perimeter of the Collar 70, between the End Edges 73, 74,
forms the Insertion Face 76; 2) A Working Surface Groove 66,
{fraction (1/16)}".times.{fraction (1/16)}", may be machined into
the Working Surface 64 of the Base Plate 61 at the intersection of
the Collar Strip End Edge 74 and the Working Surface 64. The
Working Surface Groove 66 has an outside diameter equal to the
inside diameter of the Insertion Face 76 and inside diameter
ideally about 1/3" less than the inside diameter of the Insertion
Face 76. The Working Surface Groove 66 accepts the inserted edge of
the Flanged Ring Band Stock 40; 3) A 1/2" thick.times.13/8" wide
mild steel Mating Strip 80 in a circular form has a Mating Surface
84, Mating Strip Bottom 86, a Mating Surface/Hem Edge 85, and a
Mating Face 82 at the interior perimeter of the Mating Strip 80.
The Mating Strip 80 may be a flat burned arc with an inside
diameter at the Mating Face approximately about {fraction (1/16)}"
greater than the Flanged Ring Band Stock 40 and is tack welded to
the Collar Strip End Edge 73 distal from the Working Surface 64
such that the 13/8" wide surface of the Mating Surface 84 is
parallel to the Working Surface 64; 4) the Collar 70 assembly may
be continuously welded between the Collar Strip End Edge 74 and the
Working Surface 64 (Collar Strip Second Edge Weld 78) and between
the Collar Strip End Edge 73 and the Mating Strip Bottom 86 (Mating
Strip Bottom Weld 88) via the mig welding process. The Collar 70 or
die or fixture means, receiving the Flanged Ring Band Stock 40, may
be provided by means other than described, including machining or
constructing from a single component or other combinations of
components and may have a variety of dimensions depending on the
final intended dimensions of the Circular or Oval Flanged Ring 10,
20 to be produced.
[0072] Clamping means, including for example Cam Clamps 90, as
shown in FIGS. 9A, 9B, 11, 11A and 11B, may be affixed to the
Working Surface 64 of the Base Plate 61 and positioned to rotate
and bind the inserted Flanged Ring Band Stock 40 between the clamp
cam and the inner perimeter of the Insertion Face 75, thus securing
the Flanged Ring Band Stock 40 between the Cam Clamp 90 and the
inner perimeter during the spinning, forming and trimming process.
Depending upon the size of the Circular or Oval Flanged Rings 510,
512 to be produced, there will be at a minimum two Cam Clamps 90
for 14" diameter Circular Flanged Rings 510, 512 and up to eight or
more Cam Clamps 90 for 60" diameter Circular Flanged Rings 510,
512.
[0073] The Spinning Die 60 means will be balanced and will have
material strength sufficient to permit smooth and safe rotation up
to and exceeding 3,000 rpm. Machining or other steps may be
necessary to help ensure that the Spinning Die 60 and all
structural means or supporting structural member means are truly
round and balanced in all axes in order to minimize vibration. The
Spinning Die 60 structure may, for example, include the Spinning
Die 60, a circular Adapter Plate 100 and a circular Backing Plate
110 with means for securing concentrically the Adapter Plate 100 to
the Lathe Output Shaft 50 and the Adapter Plate 100 to the Base
Plate 61 Mounting Surface 62. For the production of Circular
Flanged Rings 42" diameter and greater, means for concentrically
securing, for structural stability, the Backing Plate 110 between
the Adapter Plate 100 and the Spinning Die 60. The Adapter Plate
100, for example, may be composed of a 1/2" thick circular steel
plate 14" in diameter having an Adapter Plate Obverse and Reverse
Sides 102, 104 and having a fixture means, at the Adapter Plate
Reverse Side 104, for concentric attachment to the Lathe Output
Shaft 50 including threaded means which may be, for example, a Hub
107 providing a female thread for mating with a Lathe Output Shaft
50. The Adapter Plate 100 may, for example, have means for
concentric attachment to the Mounting Surface 62 of the Base Plate
61 including Bolt Apertures 109 from the Adapter Plate Reverse to
Obverse Sides 104, 102 having therein threaded means with the Bolt
Apertures 109 symmetrically positioned in a pattern which will be
mirrored and matched by Bolt Apertures 109 from the Mounting
Surface to the Working Surface 64 of the Base Plate 61. The
additional mass involved in the Spinning Die 60 for Circular
Flanged Rings 510, 512 of 42" diameter and greater may require
additional structural stability which may be provided, for example,
by the utilization of a Backing Plate 110 comprised of a 1" thick
circular steel plate 42" in diameter having Backing Plate Obverse
and Reverse Sides 111, 112 and mounting means for concentrically
mating with the Adapter Plate 100 and the Spinning Die 60. Mounting
means for the Backing Plate 110 may include, for example, Bolt
Apertures 109 from the Backing Plate Obverse to Reverse Side 111,
112 having threaded means therein and symmetrically positioned on a
pattern which will be mirrored and matched by Bolt Apertures 109
for the Adapter Plate 100 and the Spinning Die 60.
[0074] Two separate spinning dies 60 are required to form a
circular or oval flanged ring connector 510, 520 to be used to join
double wall ducts 532. A first spinning die may be selected in
accordance with the diameter of the first cylindrical shaped ring
to be formed. A second spinning die may be selected in accordance
with the diameter of the second circular shaped ring to be formed.
A spinning die 60 is mounted, by mounting means, on rotation means
including a lathe output shaft 50. The first workpiece in the form
of a flanged ring band stock 40 may be inserted in the spinning die
60 against and received by the insertion face 75 and the mating
face 82 and into the working surface groove 66, where it may be
secured by means including clamp means provided, for example, by
cam clamps 90. The flanged ring band stock 40 may be rotated in
preparation for the forming and trimming process.
[0075] The forming and trimming of the first flange ring involves
standard machine tools and stabilizing devices including:
[0076] (1) an internal roller 120, as shown in FIG. 12, having an
internal roller wheel 122 comprising a wheel having a perimeter
consisting of a convex wheel working surface and pivot means
attached by means to an internal roller tool fixture 124 provided,
for example, by an internal roller handle 126 permitting the wheel
to rotate in a plane 90.degree. to a longitudinal axis from an
internal roller handle first and second ends 127, 128 when the
wheel working surface is in contact with a mating flange 504, 514
portion of the flanged ring band stock 40 when clamped into the
spinning die 60 (the internal roller 120 for the preferred
embodiment of the disclosed method has a convex working surface
with a 1/2" radius and an internal roller handle 126 proximal to
the internal roller wheel 122 has five 3/4" diameter holes spaced
equally 11/4" apart);
[0077] (2) a radius roller 130, as shown in FIG. 13, having a
radius roller wheel 132 comprising a wheel having a perimeter
consisting of a convex wheel working surface and pivot means
attached by means to a radius roller tool fixture 134 provided, for
example, by a radius roller handle 136 permitting the wheel to
rotate in a plane parallel to a longitudinal axis from a radius
roller handle first and second ends 137, 138 when the wheel working
surface is in contact with a hem portion 505, 515 of the flanged
ring band stock 40 when clamped into the spinning die 60 (the
radius roller wheel 132 for the preferred embodiment of the
disclosed method has a convex working surface with a 1/8" radius
and the radius roller handle 136 proximal to the radius roller
wheel 132 has five 3/4" diameter holes spaced equally 11/4"
apart);
[0078] (3) a trim lever 140, as shown in FIG. 15, comprising a
cutting tip 142 affixed to a trim lever tool fixture 144 provided
for example by a trim lever handle 146 permitting the cutting tip
142 to extend parallel with a longitudinal axis from the trim lever
handle first to second ends 147, 148 with the cutting tip for
cutting or trimming the exterior hem 505 as the step preliminary to
the production of the return flange 506 (the cutting tip 142 for
the preferred embodiment of the disclosed method has a 1/2"
square.times.31/2" long carbide cutting tip and the trim lever
handle 146 proximal to the cutting tip 142 has five 3/4" diameter
holes spaced equally 11/4" apart);
[0079] (4) a finishing roller 150, as shown in FIG. 14, having a
finishing roller wheel 152 having a perimeter consisting of a
convex wheel working surface and pivot means attached to a
finishing roller tool fixture 154 provided, for example, by a
finishing roller handle 156 permitting the finishing roller wheel
152 to rotate in a plane parallel to a longitudinal axis from a
finishing roller handle first and second ends 157, 158 when the
wheel working surface is in contact with the return flange 506
portion of the flanged ring band stock 40 when clamped into the
spinning die 60 (the finishing roller wheel 152 for the preferred
embodiment of the disclosed method has a convex working surface
with a 1/2" radius and the finishing roller handle 156 proximal to
the finishing roller wheel 152 has five 3/4" diameter holes spaced
equally 11/4" apart).
[0080] The internal roller 120, radius roller 130, trim lever 140,
and finishing roller 150 are urged against the appropriate portions
of the flanged ring band stock 40 by machining process means,
including by manual/hand manipulated means, automated machine tool
means operated and controlled by computers and computer programs,
and other process control systems and other machine tool processes.
Leverage, to manually urge the above machine tools in their
function may, for example, be facilitated by the following:
[0081] (1) Tool rest 170, as shown in FIG. 17, which is mounted in
a position opposing the rotating spinning die 60 at a position
where the indicated machine tools may be brought into contact with
the flanged ring band stock 40 and undertake the machining steps
described. The tool rest 170 may be mounted, for example, on a
lathe cradle opposing the spinning die 60 within which the various
machine tools will operate on a flanged ring band stock 40. The
tool rest 170 consists, in the preferred embodiment, of a mild
steel block 37" long.times.3" thick.times.4" wide with the tool
rest top 172 having 30 apertures sized to receive a 3/4" diameter
pin and spaced 11/8" apart along the length of the tool rest top
172;
[0082] (2) A power lever 160, as shown in FIG. 16, 16A, and 16B
comprising a power lever head 161 having a power lever head top and
bottom surface 162, 163, a top surface pin 164 3/4"
diameter.times.3/4" long extending from the power lever head top
surface 162 , and a bottom surface pin 165 3/4" diameter.times.3/4"
long extending from the power lever head bottom surface 163. The
top and bottom surface pins 164, 165 are ideally parallel to an
offset from each other. The power lever head 161 is affixed to a
tool fixture provided, for example, by a power lever handle 167.
The power lever 160 is used, in the manual/hand production
procedure, to provide the pivot point about which the machine tools
are operated to attain the leverage required to form, stretch, and
trim the flanged ring band stock 40.
[0083] In one embodiment of the method of production by hand, a
guide plate means may be affixed following formation of the
exterior or interior mating flange 504 (or the interior mating
flange 514, if forming the second cylindrical shaped ring), to a
lathe tail stock 188, and is bound by friction against the exterior
or interior mating flange 504, 514 portion of the flanged ring band
stock, thereby securing the flanged ring band stock 40 between the
mating surface 84 and the guide plate means. The guide plate means
may be provided, for example, by a follow block 180, as shown in
FIGS. 19 and 19A, preferably comprised of two cylindrical cut
plywood or other material pieces 182, each 3/4" thick, secured
together to form a 11/2" thick combined plywood or other material
piece, having an outside diameter ideally substantially equal to
the outside diameter of the mating surface 84. A 1" thick, 6"
diameter mild steel tail stock plate 184 may have a centrally
positioned tail stock aperture 186, sized to receive the lathe tail
stock 188, which is concentrically affixed by means, for instance
bolt means, to the circular cut plywood or other material pieces
182.
[0084] One method disclosed for the production of the circular
flanged ring 510 is as follows:
[0085] I. The adapter plate 100 is mounted to the lathe output
shaft 50.
[0086] II. The first spinning die 60 used to form the first
cylindrical shaped ring 511 (optionally with backing plate 110 when
the first cylindrical shaped ring 511 diameter is 42" and greater)
is mounted to the adapter plate 100.
[0087] III. A flanged ring band stock 40 is inserted into the first
spinning die 60 and secured by clamps, as shown in FIG. 18.
[0088] IV. A tool rest 170 is mounted on the lathe cradle. A power
lever 160 via a bottom surface pin 165 is inserted into an aperture
at the tool rest top 172.
[0089] V. The lathe is powered causing the spinning die 60 to
revolve.
[0090] VI. An internal roller 120 is positioned on the top surface
pin 164 of the power lever via an aperture in the internal roller
handle 126. The internal roller wheel working surface 122 is
positioned on the inside of the flange ring band stock 40 at the
outer {fraction (1/16)}" of flange ring band stock 40 distal from
the working surface 62 and causes the portion of the flange ring
band stock 40 extending past the mating face 82 to be stretched and
bent against the mating surface 84, forming an exterior mating
flange 504, as shown in FIG. 18A. The portion of the flange ring
band stock 40 received into the collar 70 and against the insertion
face 75 is the outer insertion flange 503 forming approximately a
90.degree. angle with the exterior mating flange 504, as shown in
FIG. 18A. The portion of the flange ring band stock 40 extending
from the exterior mating flange 504 portion of the workpiece distal
from the outer insertion flange 503 and toward the portion of the
flange ring band stock 40 which will include the exterior hem 505
is bent against the mating surface/hem edge 85 forming an
approximate 20.degree. angle between the exterior hem 505 portion
and the exterior mating flange 504, as shown in FIG. 18A. This
concludes the machine tool activity required of the internal roller
120.
[0091] VII. Upon conclusion of forming by the internal roller 120,
a follow block 180 optionally may be positioned against the mating
surface 84. The portion of the flange ring band stock 40 distal
from the outer insertion flange 503 and exterior mating flange 504,
which will form the exterior hem 505 and return hem 506 extends
beyond the mating surface 84 and the follow block 180 and is
accessible to machine tool operations. The interior roller 120 is
removed from the power lever 160 and replaced with a radius roller
130. The radius roller wheel 132 convex working surface is
positioned at a 45.degree. angle to the mating surface 84 and
initially is placed in contact with the follow block 180 in order
to bring the radius roller wheel 132 up to speed. The radius roller
wheel 132 is then forced onto the exposed portion of the flange
ring band stock 40 at the mating surface/hem edge 85 causing the
metal to stretch in contact with and forming the contour of the hem
surface 76 forming, proximal to the exterior mating flange 504, the
exterior hem 505, as shown in FIG. 18B. That portion of the flange
ring band stock 40 most distal from the outer insertion flange 503
may form an approximately 90.degree. angle with the exterior hem
505 and constitutes the portion of the flange ring band stock 40
which will be formed into the return flange 506, as shown in FIG.
18B.
[0092] VIII. The radius roller 130 is removed from the power lever
160 and replaced with the trim lever 140. The cutting tip 142 is
placed in contact with the outside edge of the portion of the
flange ring band stock 40 which will form the return flange 506 and
cuts away any metal sufficient to leave approximately 3/8" for the
return flange 506.
[0093] IX. The trim lever 140 is removed from the power lever 160
and replaced with the finishing roller 150. The right side of the
finishing roller wheel 152 is placed in contact with the edge of
the flange ring band stock 40 most distal from the outer insertion
flange 503, at an approximate 45.degree. angle with the flange ring
band stock 40 which has been trimmed, allowing the finishing roller
wheel 152 to be brought up to the speed of the spinning die 60. The
finishing roller wheel 152 is urged against the edge of the flange
ring band stock 40 causing the metal to fold back and in contact
with the exterior hem 505, thus forming return flange 506.
[0094] X. The lathe is turned off and the completed first
cylindrical flanged ring 511 is removed from the spinning die
60.
[0095] XI. The first spinning die 60 used to form the first
cylindrical shaped ring 511 is removed to the adapter plate
100.
[0096] XII. The second spinning die 60 used to form the second
cylindrical shaped ring 512 (optionally with backing plate 110 when
the first cylindrical shaped ring 512 diameter is 42" and greater)
is mounted to the adapter plate 100.
[0097] XIII. A flanged ring band stock 40 is inserted into the
second spinning die 60 and secured by clamps, as shown in FIG.
18.
[0098] XIV. A tool rest 170 is mounted on the lathe cradle. A power
lever 160 via a bottom surface pin 165 is inserted into an aperture
at the tool rest top 172.
[0099] XV. The lathe is powered causing the spinning die 60 to
revolve.
[0100] XVI. An internal roller 120 is positioned on the top surface
pin 164 of the power lever via an aperture in the internal roller
handle 126. The internal roller wheel working surface 122 is
positioned on the inside of the flange ring band stock 40 at the
outer {fraction (1/16)}" of flange ring band stock 40 distal from
the working surface 62 and causes the portion of the flange ring
band stock 40 extending past the mating face 82 to be stretched and
bent against the mating surface 84 forming an interior mating
flange 514, as shown in FIG. 18A. The portion of the flange ring
band stock 40 received into the collar 70 and against the insertion
face 75 is the inner insertion flange 513 forming approximately a
90.degree. angle with the interior mating flange 514, as shown in
FIG. 18A. The portion of the flange ring band stock 40 extending
from the interior mating flange 514 portion of the workpiece distal
from the inner insertion flange 513 and toward the portion of the
flange ring band stock 40 which will include the interior hem 515
is bent against the mating surface/hem edge 85 forming an
approximate 20.degree. angle between the interior hem 515 portion
and the interior mating flange 514, as shown in FIG. 18A. This
concludes the machine tool activity required of the internal roller
120.
[0101] XVII. Upon conclusion of forming by the internal roller 120,
a follow block 180 is positioned against the mating surface 84. The
portion of the flange ring band stock 40 distal from the inner
insertion flange 513 and interior mating flange 514, which will
form the exterior hem 515 extends beyond the mating surface 84 and
the follow block 180 and is accessible to machine tool operations.
The interior roller 120 is removed from the power lever 160 and
replaced with a radius roller 130. The radius roller wheel 132
convex working surface is positioned at a 45.degree. angle to the
mating surface 84 and initially is placed in contact with the
follow block 180 in order to bring the radius roller wheel 132 up
to speed. The radius roller wheel 132 is then forced onto the
exposed portion of the flange ring band stock 40 at the mating
surface/hem edge 85 causing the metal to stretch in contact with
and forming the contour of the hem surface 76 forming, proximal to
the interior mating flange 514, the interior hem 515, as shown in
FIG. 18B.
[0102] XIX. The lathe is turned off and the completed second
cylindrical flanged ring 512 is removed from the spinning die
60.
[0103] The method disclosed for the production of the Oval Flanged
Ring 600 may be as follows:
[0104] I. A Circular Flanged Ring 510 is produced and is cut along
a diameter producing two Semi-circular Flanged Ring Portions
602.
[0105] II. SMACNA T24 Linear Segments 604 are produced with the
SMACNA T24 Flange Profile I by roll forming or other method.
[0106] III. The SMACNA T24 Linear Segments 604 are affixed by
means, including welding, to the Semi-circular Flanged Ring
Portions 602 at joints 606 to form the Oval Flanged Ring as shown
in FIGS. 5 and 5A.
[0107] FIG. 21 illustrates an alternative to the foregoing
described method for producing the first cylindrical shaped ring
and the second cylindrical shaped ring 511', 512'. In the
alternative method, both the exterior and the interior mating
flanges 504', and 514' can be produced as described above, and then
the outer perimeter of the mating flange trimmed to provide a
desired maximum diameter. Thereafter the exterior hem 505' and the
return flange 506' can be formed as a separate component by various
methods, such as bending or rolling flat stock over on itself and
then rolling the flat stock into a circular ring. The ends of the
rolled, bent-over, or turned or rolled flat stock could be butt
welded together, and then welded to the outer perimeter of the
exterior mating flange 504'. The interior hem 515' may also be
formed as a separate component by a method such as rolling flat
stock into a circular ring, butt welding the ends, and attaching
the circular ring to the outer perimeter of the interior mating
flange 514'.
[0108] The exterior hem 505' and return flange 506' could instead
be formed by a stamping process beginning with a flat, annular
workpiece. Thereafter, the formed hem and flange could be welded to
the outer perimeter of the exterior mating flange 504'. An interior
hem 515' could also be stamped separately and then welded to the
outer perimeter of the interior mating flange 514'. Producing the
exterior hem 505' and return flange 506' as a separate component or
the interior hem 515' as a separate component and then attaching
such component to the outer perimeter of either the exterior or
interior mating flange 504', 514' may not be as efficient as
spin-forming the entire flange ring 510' as described above with
respect to flange ring 510'. Also, this "2-step" method may result
in a certain amount of distortion when the separately formed
components are welded to the mating flanges 504', 514'.
Nonetheless, the 2-step method may be carried out with less
sophisticated tooling than required by the spinning method
described above.
[0109] As a further alternative, it is possible to produce the
flanged ring 510" shown in FIG. 22 by forming the insertion flanges
503", 513" as one component and the mating flanges 504", 514", hems
505", 515", and return flange 506" as a second component. The
insertion flanges 503", 513" can be produced as shown in FIGS.
10-10B and as described above. The mating flanges 504", 514", hems
505", 515", and return flange 506" could be produced by
roll-forming using generally the techniques discussed above, or
also perhaps by stamping. Thereafter, the two components can be
assembled by welding the inside perimeter of each mating flange to
the end edge of each insertion flange. This alternative technique
may suffer from the same disadvantages of the technique shown in
FIG. 21 above, including a larger number of manufacturing steps as
well as significant distortion or warpage of the flanged ring 510"
due to the welding operation. On the other hand, it may be possible
to produce the flanged ring 510" using less sophisticated tooling
than used to produce the flanged ring 510", as described above.
[0110] FIGS. 23A, 23B, 23C, 23D, 23E, and 23F illustrate an
alternative to the foregoing described methods for producing a
flanged ring 510'". In this alternative method, an exterior and an
interior mating flange 504'", 514'" can be spin formed as described
above. Thereafter, the hem sections 505'", 515'" can be formed by a
first roller set 200 consisting of a first roller assembly 202
composed of a major diameter roller 204 and a side-by-side smaller
diameter roller 206, both mounted on a rotatable shaft 208. The
first roller set 200 also includes a second roller assembly 210
consisting of a roller 212 mounted on a rotatable shaft 214. The
rotatable roller shafts 208 and 214 may be moved towards and away
from each other in a substantially parallel orientation in a
well-known manner. When the shafts are moved toward each other, the
roller 212, positioned at the side of roller 204, forms the
exterior and interior hem sections 505'", 515'" by capturing each
hem section between the adjacent face sections of the rollers 204
and 212. In addition, a precursor to the return flange 506'" may be
formed between the outer diameter of roller 212 and the outer
diameter of roller 206. See FIG. 23B wherein a hem section 505'"
extends substantially laterally and optionally perpendicular to a
mating flange 504'" and the precursor to the return flange 506'"
extends substantially perpendicular to the adjacent end of the hem
section.
[0111] The partially formed Flanged Ring 511'" of FIG. 23B may be
placed in a roller set 220 of FIG. 23C for further processing. The
roller set 220 includes a die roller assembly 222 composed of a die
roller 224 mounted on a rotatable shaft 226. The die roller 224 may
have a groove formed around its outer perimeter in the shape of a
half "V" composed of a vertical face 228 and a diagonal face 230.
The roller set 222 may include a second roller assembly 232
composed of a cylindrical roller 234 mounted on a rotatable shaft
236. The roller assemblies 224 and 232 are capable of moving
towards and away from each other while the rotatable shafts 226 and
236 remain substantially parallel to each other. As shown in FIG.
23C, the partially formed Flanged Ring 511'" from FIG. 23B is
positioned relative to roller 224 so that hem section 505'" is
adjacent vertical face 228 of roller 224. Thereafter, the roller
sets 222 and 232 may be moved towards each other as the rollers 224
and 234 rotate relative to each other thereby causing the return
flange section 506'" to assume the orientation of roller face 230
relative to roller face 228, as shown in FIG. 23D.
[0112] Thereafter, the flanged ring in the configuration of FIG.
23D may be further formed by roller set 240 shown in FIG. 23E.
Roller set 240 consists of a pair of roller assemblies 242 and 244
each composed of a roller 246 and 248 carried by a corresponding
rotatable shaft 250 and 252. As shown in FIG. 23E, the hem section
505'" and the partially formed return flange 506'" may be placed
between the two rollers 246 and 248 and then the two rollers are
moved relatively towards each other while rotating, thereby to
pinch the hem section and return flange therebetween so that the
return flange closely overlies the hem section and thereby
completing the formation of the flanged ring 511'", as shown in
FIG. 23F.
[0113] Although only the method of making the first flanged ring
511'" is shown, the second flanged ring can be constructed from the
same initial method, but only the step shown in FIG. 23A is needed
since the flanged ring 511'" does not have a return flange.
[0114] FIGS. 24A, 24B, 24C, and 24D illustrate another method of
forming an outer flanged ring 511"" in accordance with the present
invention. As illustrated, the exterior mating flange 504"" of the
flanged ring 511"" may be formed using a spin forming method, such
as described above. Thereafter, the outer marginal portion of the
mating flange may be placed in roller set 300 to partially form
each hem section 505"" and return flange 506"", as shown in FIG.
24B. The roller set 300 may include a first roller assembly 302
consisting of a roller die 304 mounted on the rotatable shaft 306.
A "V" shaped groove 308 extends around the circumference of the
roller die 304 to match the outer perimeter profile of a roller die
310 mounted on rotatable shaft 312 of a roller assembly 314. The
roller assemblies 302 and 314 are capable of moving towards and
away from each other while their respective shafts 306 and 302
rotate and maintain an orientation substantially parallel to each
other. As a consequence, when the outer marginal portion of the
exterior mating flange 504"" is placed in alignment with groove 308
and then the roller dies 304 and 310 rollably engage with each
other they cooperatively form hem section 505"" and return flange
506"" in the orientation shown in FIG. 24B.
[0115] Thereafter, the partially formed flanged ring shown in FIG.
24B may be further worked by roller set 340 shown in FIG. 24C. The
roller set 340 corresponds to the roller set 240 shown in FIG. 23E,
with the description set forth above with respect to FIG. 23E
applying to FIG. 24C, but with the part numbers increased by 100.
Thus, such description will not be repeated. The result of roller
set 340 is a finished flanged ring 511"" as shown in FIG. 24D.
Although only the method for making the first circular flanged ring
511'" is shown, the second circular flanged ring 512"" can be
constructed from the same method without the formation of the
return flange 506"".
[0116] It will be appreciated that other combinations of roller
sets could be utilized to form the hem section and return flange of
the flanged ring, other than as illustrated above in FIGS. 23 and
24. Although use of such rolling techniques may not be as efficient
as spin forming the entire flange ring in the manner described
above, utilizing rolling processes may enable the flange ring to be
manufactured with less expensive tooling or with tooling already on
hand as opposed to requiring extensive spin form tooling.
[0117] The foregoing description is related to the connectors for
double wall ducting, including as shown in FIGS. 21 through 25. The
present invention may also be used with respect to flanged
connectors for single wall ducting as shown in FIGS. 1-4.
[0118] While preferred embodiments of the present invention have
been shown and described, it will be apparent to those skilled in
the art that many changes and modifications may be made without
departing from the invention in its broader aspects. The appended
claims are therefore intended to cover all such changes and
modifications as fall within the true spirit and scope of the
invention.
* * * * *