U.S. patent application number 10/010714 was filed with the patent office on 2002-10-03 for integral ductwork diffuser.
This patent application is currently assigned to OVALFORMER LLC. Invention is credited to Froning, Mark A., Moyers, Gregory C., Price, Miller S..
Application Number | 20020139160 10/010714 |
Document ID | / |
Family ID | 22962938 |
Filed Date | 2002-10-03 |
United States Patent
Application |
20020139160 |
Kind Code |
A1 |
Price, Miller S. ; et
al. |
October 3, 2002 |
Integral ductwork diffuser
Abstract
Apparatus and a corresponding method for forming from a strip of
sheet metal stock material a length of spiral duct that includes an
integral diffuser. A perforator forms perforations in the strip at
at least selected intervals. A machine forms the strip, after
perforation, into spiral seamed duct.
Inventors: |
Price, Miller S.;
(Morristown, TN) ; Froning, Mark A.; (Fletcher,
NC) ; Moyers, Gregory C.; (Arden, NC) |
Correspondence
Address: |
STEVEN C. SCHNEDLER
CARTER & SCHNEDLER, PA
56 CENTRAL AVE., SUITE 101
PO BOX 2985
ASHEVILLE
NC
28802
US
|
Assignee: |
OVALFORMER LLC
Arden
NC
|
Family ID: |
22962938 |
Appl. No.: |
10/010714 |
Filed: |
December 7, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60254103 |
Dec 8, 2000 |
|
|
|
Current U.S.
Class: |
72/49 |
Current CPC
Class: |
B21C 37/124 20130101;
B21C 37/121 20130101; F24F 13/0245 20130101; F16L 9/165 20130101;
F24F 2013/0608 20130101; B21C 37/157 20130101; B21C 37/126
20130101 |
Class at
Publication: |
72/49 |
International
Class: |
B21C 037/12 |
Claims
What is claimed is:
1. Apparatus for forming from a strip of sheet metal stock material
a length of spiral duct that includes an integral diffuser, said
apparatus comprising: a perforator for forming perforations in the
strip at at least selected intervals; and a machine for forming the
strip, after perforation, into spiral seamed duct.
2. The apparatus of claim 1, wherein said perforator forms clusters
of perforations at intervals corresponding to the circumference of
the spiral seamed duct being formed.
3. The apparatus of claim 1, wherein said perforator comprises a
punching roll.
4. The apparatus of claim 1, wherein said perforator comprises a
stationary punch.
5. The apparatus of claim 1, which further comprises a controller
connected for coordinating operation of said perforator and of said
machine for forming the strip into spiral seamed duct.
6. Apparatus for forming, from a strip of sheet metal stock a
length of 360.degree. perforated spiral duct, said apparatus
comprising: a perforator for forming perforations in the strip in a
continuous manner and a machine for forming the strip, after
perforation, into spiral seamed duct.
7. A method for forming a length of spiral duct that includes an
integral diffuser, said method comprising: providing a strip of
sheet metal stock material; perforating the strip at at least
selected intervals; and employing a machine to form the strip into
spiral seamed duct.
8. The method of claim, which comprises perforating the strip to
form clusters of perforations at intervals corresponding to the
circumference of the spiral seamed duct being formed.
Description
CROSS-REFERENCE TO PROVISIONAL PATENT APPLICATION
[0001] The benefit of U.S. Provisional Patent Application Ser. No.
60/254,103, filed Dec. 8, 2000, is claimed.
BACKGROUND OF THE INVENTION
[0002] The invention relates to air diffusers employed in
combination with round spiral and flat oval ductwork, such as is
employed in heating, ventilation and air conditioning (HVAC) system
applications.
[0003] Round, thin-walled spiral seamed metal ducts made from
strips of sheet metal are widely employed in heating and air
conditioning installations, as well as in other air ducting
installations. Such spiral duct is efficiently produced in desired
lengths by Tubeformer machines, manufactured for example, by
Spiral-Helix, Inc. of Buffalo Grove, Ill., and described for
example in Castricum U.S. Pat. Nos. 4,567,742; 4,706,481 and
4,711,110. Another machine for producing spiral seamed pipe is
disclosed in Price et al U.S. Provisional Patent Application Ser.
No. 60/264,387, filed Jan. 26, 2001. Another machine for producing
spiral seamed pipe is disclosed in Price et al U.S. Provisional
Patent Application Ser. No. 60/264,387, filed Jan. 26, 2001. Spiral
duct has a number of advantages, in both ease of installation and
performance.
[0004] Typically, a strip of sheet metal 5.394 inches (137 mm) wide
is supplied to the Tubeformer machine. An initial stage of the
Tubeformer machine comprises a set of flange forming rolls which
prepare the edges of the strip for subsequently formed spiral lock
seams. Thereafter, the strip is rolled into formed spiral lock
seams. Thereafter, the strip is rolled into the desired spiral duct
size, and the spiral lock seams are completed.
[0005] In some installations limited space prevents the use of
round spiral duct. Accordingly, flatter ductwork which is oval in
cross-section is employed, also known as flat oval. As the tube
former machines produce round and not oval ductwork, a separate
machine, known as an ovalizer, is ordinarily employed to form round
ductwork to oval. A suitable ovalizer is disclosed in Price et al
U.S. Pat. No. 6,000,260.
[0006] Air diffusers are typically employed at appropriate
locations along the length of a spiral duct, either round or flat
oval. A typical conventional practice is to install a grill box. A
typical grill box takes the form of a rectangular box, open at the
front and back, attached to the spiral ductwork at the location of
a corresponding rectangular cutout in the ductwork, and a grill
attached. Thus, a four-step operation is required: (1) The ductwork
is manufactured. (2) A hole for the grill box is cut. (3) The grill
box is fabricated and installed, secured either by welding or by
sheet metal screws. (4) Finally, a suitable grill is purchased and
installed.
[0007] A variation, which avoids the need for the separate grill
box, is to directly attach a semi-cylindrical grill to the side of
a spiral duct, over a rectangular opening. An example is a
Duct-D-Fuser.TM. grill, manufactured by McGill Air Flow Corporation
of Groveport, Ohio. In this variation, three steps are required:
(1) Manufacture the ductwork. (2) Cut a hole for the perforated
grill. (3) Purchase and install the grill.
SUMMARY OF THE INVENTION
[0008] In an exemplary embodiment, apparatus for forming from a
strip of sheet metal stock material a length of spiral duct that
includes an integral diffuser includes a perforator forming
perforations in the strip at at least selected intervals, and a
machine for forming the strip, after perforation into spiral seamed
duct.
[0009] A corresponding method for forming a length of spiral duct
that includes an integral diffuser embodying the invention includes
the steps of providing a strip of sheet metal stock material,
perforating the strip at at least selected intervals, and employing
a machine to form the strip into spiral seamed ducts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a three dimensional view of apparatus embodying
the invention;
[0011] FIG. 2 is a conceptual diagram depicting the operation of
one embodiment;
[0012] FIG. 3 is a plan view of a perforator;
[0013] FIG. 4 is a side view of a portion of the FIG. 3
perforator;
[0014] FIG. 5 is a conceptual view, similar to that of FIG. 2,
depicting another embodiment of the invention;
[0015] FIG. 6 is a side view of another apparatus embodying the
invention, including a stationary punch assembly; and
[0016] FIG. 7 is a representation of an exemplary punching
pattern.
DESCRIPTION
[0017] Embodiments of the invention eliminate the separate grill
and grill box by perforating the sheet metal stock as part of the
spiral forming operation, either before or after the flange forming
rolls.
[0018] FIG. 1 shows an apparatus 20 embodying the invention. A
strip of sheet metal stock material 22 enters the apparatus 20 as
indicated by arrow 24. Spiral seamed duct 26, including an integral
diffuser 28, is produced by the apparatus.
[0019] The apparatus 20 more particularly includes a perforator 30
for forming perforations in the strip 22 at at least selected
intervals, such as the perforations 52. Various forms of perforator
30 are described in greater detail hereinbelow. Following the
perforator is a machine, generally designated 34, for forming a
strip into the spiral seamed duct 26. The machine includes a flange
forming roller station 36, a passive feed section 38, and a bending
roller station 40, including a seaming roller. The particular
machine 34 illustrated is disclosed in the above-referenced Price
et al U.S. Provisional Application Ser. No. 60/264,387. However,
the machine 34 may just as well be a Tubeformer machine, such as is
disclosed in the above-referenced Castricum U.S. Pat. Nos.
4,567,742; 4,706,481 and 4,711,110. The apparatus 20 additionally
includes a controller 42 for coordinating the operation of the
perforator 30 and of the spiral duct-forming machine 34.
[0020] During operation, and under the control of the controller
42, the perforator 30 forms clusters of perforations, such as the
perforations 52, at intervals corresponding to the circumference of
the spiral seamed duct 26 being formed. The resultant diffuser 28
formed has a width corresponding to several strips.
[0021] With reference to FIG. 2, conceptually illustrated is the
operation of one embodiment of apparatus 20, including the
perforator 30 and spiral-forming machine 34. Thus, the strip 22 of
sheet metal enters the apparatus 20. In a spiral-forming zone 60
the sheet metal strip 22 is wound to form the spiral duct 26. At 62
spiral lock seams are formed, all as is known in the art.
[0022] In embodiments of the invention, in a perforation zone 64
perforations are formed in the sheet metal strip 22, in an
appropriate pattern, as represented by separate clusters 66, 68 and
70. The clusters 66, 68 and 70 of perforations are appropriately
located, under the direction of the controller 42, such that, upon
formation of the spiral ductwork, a desired grill or diffuser
pattern, as is represented at 28 results.
[0023] Any suitable process may be employed for making the
perforation clusters 66, 68 and 70.
[0024] With reference to the plan view of FIG. 3 and the side view
of FIG. 4, an exemplary device embodying the invention for forming
the perforations takes the form of a rolling punch, generally
designated 80. The rolling punch 80 includes a punching roll 82 and
an opposed die roll 84, with the strip 22 of sheet metal stock
passing between.
[0025] In FIG. 3, a motor 86 drives the punching roll 82 through a
gearing reducer 88, under the control of a suitable electronic
controller 90.
[0026] The motor 86 and thus the punching roll 82 is programmed to
be engaged when required, and make the necessary size perforation
for the application.
[0027] Referring again to FIG. 2, the perforation cluster 68
extends all the way across the sheet metal strip 22, while the
perforation clusters 66 and 70 extend only part way across. To form
the perforation clusters 66 and 70 extending only part way across,
in an exemplary embodiment the punching roll 82 is arranged, by
means of a splined drive shaft 92 and an actuating cylinder 94 to
move transversely so that the punch roll 82 punches only a portion
of the width of the sheet metal strip 22.
[0028] With reference to FIG. 5, conceptually illustrated is the
operation of another apparatus 100 embodying the invention. FIG. 6
illustrates the apparatus 100 in elevational view.
[0029] In FIG. 6 the apparatus 100 includes the machine 34 for
forming spiral metal duct as is described herein above with
reference to FIGS. 1 and 2. In FIG. 6 as a matter of convenience,
the controller 42 is within the machine 34.
[0030] The apparatus 100 includes a perforator in the form of a
stationary punch 102, including a set of servo-driven feed rolls
104, and a stationary punch assembly 106, including a punch 108
driven by an hydraulic cylinder 110, and a corresponding die block
112. FIG. 8 illustrates an exemplary punching pattern of the
stationary punch 106. Each cycle of the punch 106 produces 11
perforations, arranged in two rows. A typical perforation diameter
is {fraction (5/16)} inch.
[0031] Movement of the strip 22 must be interrupted for punching,
while the spiral duct forming machine 34 proceeds relatively
continuously. Accordingly, an idle loop 114 is formed by the strip
22, prior to entering the spiral duct-forming machine 34.
[0032] It will be appreciated that embodiments of the invention
allow the grill or perforation to be automatically installed into
the ductwork during the fabrication phase of the ductwork. The
ductwork is simply sent to a job site, and is installed without any
additional labor or material cost.
[0033] Alternatively, mobile apparatus can be employed at the job
site to perforate a strip of sheet metal stock material and form
spiral seamed ductwork.
[0034] The punching system can also be used to fabricate ductwork
for sound attenuation or 360.degree. perforated diffusers.
Conventionally, attenuation ductwork is ordered prepunched from a
steel mill. This pre-punched steel costs more than solid steel, and
requires the fabricator to stock two different types of metal.
Embodiments of the invention permit the perforated product to be
made on the same machine, without buying special stock.
[0035] In a sequence of operation, a machine operator receives an
order for ductwork, with diffuser locations specified. The operator
then programs the machine via the controller 40, which is
programmable, to locate a perforated section of ductwork at the
predetermined location.
[0036] As the machine begins operation, coiled sheet metal stock 22
is fed into the machine, and proceeds through the flange forming
rollers and through the perforation zone until it is received by
the spiral forming zone, where the spiral ductwork is actually
formed.
[0037] When portions of the sheet metal stock material which are to
be punched proceed through the perforation zone 64, the punching
wheel 82 or punch assembly 102 is activated to punch the material
for the resultant perforated ductwork.
[0038] While specific embodiments of the invention have been
illustrated and described herein, it is realized that numerous
modifications and changes will occur to those skilled in the art.
It is therefore to be understood that the appended claims are
intended to cover all such modifications and changes that fall
within the true spirit and scope of the invention.
* * * * *