U.S. patent application number 11/195390 was filed with the patent office on 2005-12-22 for pliable air duct with dust and condensation repellency.
Invention is credited to Gebke, Kevin J..
Application Number | 20050282488 11/195390 |
Document ID | / |
Family ID | 25492056 |
Filed Date | 2005-12-22 |
United States Patent
Application |
20050282488 |
Kind Code |
A1 |
Gebke, Kevin J. |
December 22, 2005 |
Pliable air duct with dust and condensation repellency
Abstract
A fabric air duct with main discharge openings includes
additional, much smaller openings that help ventilate the surface
of the duct. Ventilating the surface of the duct with a slight yet
even amount of airflow helps inhibit the accumulation of condensate
and dust on the surface of the duct. In some embodiments, the duct
includes a pliable sheet consisting of a rather porous fabric base
material. To achieve an appropriately low level of airflow, a
coating on the fabric reduces, but does not eliminate the fabric's
porosity. A calendering process then reduces the porosity even
further. In some embodiments, the calendering process occurs before
the coating process. In other embodiments, the pliable sheet is
substantially air impermeable, except for its main discharge
openings. The sheet is then perforated with numerous smaller
openings to achieve the desired amount of surface ventilation. In
yet other embodiments, an emorizing or sueding process is used to
abrade or nap the surface of a porous or non-porous base material
to create a pliable sheet having a desired amount of porosity. From
any of these processes, air ducts of various shapes may be formed,
including air ducts that are circular, 1/2 round, and 1/4 round in
shape, as well as air ducts having a non-uniform cross-sectional
shape across their lengths.
Inventors: |
Gebke, Kevin J.; (Dubuque,
IA) |
Correspondence
Address: |
HANLEY, FLIGHT & ZIMMERMAN, LLC
20 N. WACKER DRIVE
SUITE 4220
CHICAGO
IL
60606
US
|
Family ID: |
25492056 |
Appl. No.: |
11/195390 |
Filed: |
August 2, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11195390 |
Aug 2, 2005 |
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10441904 |
May 19, 2003 |
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6958011 |
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10441904 |
May 19, 2003 |
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09951717 |
Sep 13, 2001 |
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6565430 |
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Current U.S.
Class: |
454/306 ;
138/145 |
Current CPC
Class: |
F16L 11/02 20130101;
Y10S 454/903 20130101; F24F 13/068 20130101; F24F 13/0218 20130101;
F24F 13/0245 20130101; F24F 2013/0608 20130101 |
Class at
Publication: |
454/306 ;
138/145 |
International
Class: |
A61F 005/00; F24F
013/06; F24F 007/00; F24F 013/08; F16L 009/14 |
Claims
We claim:
1. An air duct, comprising a pliable sheet configured to convey
air, wherein the pliable sheet includes a fabric base material that
is porous and a coating on the fabric base material that reduces
the porosity of the fabric base material yet leaves the pliable
sheet porous, wherein the pliable sheet is formed into a tubular
shape and wherein the air duct defines a plurality of discharge
openings that provide a first open area and the porosity of the
pliable sheet provides a second open area with the first open area
being greater than the second open area.
2. The air duct of claim 1, wherein the first open area is at least
twice as great as the second open area.
3. The air duct of claim 1, wherein the fabric base material
consists essentially of polyester.
4. The air duct of claim 1, wherein the coating consists
essentially of acrylic.
5. The air duct of claim 1, wherein the coating consists
essentially of polyurethane.
6. The air duct of claim 1, wherein the pliable sheet is
anti-microbial.
7. The air duct of claim 1, wherein the pliable sheet is at least
flame retardant.
8. The air duct of claim 1, wherein the porosity of the pliable
sheet is adapted to convey air therethrough at a rate of one to
four CFM/ft.sup.2 when a 0.02 psia pressure differential exists
across the pliable sheet.
9. A method of creating an air duct, comprising: applying a coating
on a fabric base material to create a pliable sheet that is air
permeable; applying pressure to the pliable sheet to reduce its air
permeability; and configuring the pliable sheet to convey air.
10. The method of claim 9, further comprising forming the pliable
sheet into a tubular shape.
11. The method of claim 9, further comprising heating the pliable
sheet while applying pressure to the pliable sheet.
12. The method of claim 11, wherein heating the pliable sheet
involves heating one side of the pliable sheet more than an
opposite side of the pliable sheet.
13. The method of claim 9, wherein applying pressure to the pliable
sheet involves calendering.
14. The method of claim 9, wherein the air permeability of the
pliable sheet is such that the pliable sheet is able to convey air
therethrough at a rate of one to four CFM/ft.sup.2 when a 0.02 psia
pressure differential exists across the pliable sheet.
15. The method of claim 9, wherein the fabric base material
consists essentially of polyester.
16. The method of claim 9, wherein the coating consists essentially
of acrylic.
17. The method of claim 9, wherein the coating consists essentially
of polyurethane.
18. The method of claim 9, wherein the pliable sheet is
anti-microbial.
19. The method of claim 9, wherein the pliable sheet is at least
flame retardant.
20. A method of creating an air duct, comprising: applying a
coating on a fabric base material to create a pliable sheet;
perforating the pliable sheet to create a plurality of perforations
having a first open area; and forming the pliable sheet to help
create a tube that defines a plurality of discharge openings having
a second open area that is greater than the first open area.
21. The method of claim 20, wherein upon perforating the pliable
sheet, the plurality of perforations are created more by displacing
material within the pliable sheet than by removing material from
the pliable sheet.
22. The method of claim 20, wherein the second open area is at
least twice as great as the first open area.
23. The method of claim 20, wherein the fabric base material
consists essentially of polyester.
24. The method of claim 20, wherein the coating consists
essentially of acrylic.
25. The method of claim 20, wherein the coating consists
essentially of polyurethane.
26. The method of claim 20, wherein the pliable sheet is
anti-microbial.
27. The method of claim 20, wherein the pliable sheet is at least
flame retardant.
28. The method of claim 20, wherein the plurality of perforations
allow the pliable sheet to convey air therethrough at a rate of one
to four CFM/ft.sup.2 when a 0.02 psia pressure differential exists
across the pliable sheet.
29. The method of claim 20, wherein the tubular shape has a
circumference and the plurality of perforations are distributed
over most of the circumference.
30. The method of claim 20, wherein the plurality of discharge
openings is able to pass more than twenty times as much air as the
plurality of perforations.
31. The method of claim 20, wherein the plurality of perforations
have a distribution of between 100 and 2000 perforations per
square-inch.
32. The method of claim 20, wherein each perforation of the
plurality of perforations has an effective diameter that is less
than a material thickness of the pliable sheet.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 10/441,904, filed May 19, 2003, which is a continuation-in-part
of U.S. application Ser. No. 09/951,717, filed on Sep. 13, 2001,
now U.S. Pat. No. 6,565,430, both of which are incorporated herein
by reference in their entirety.
FIELD OF THE INVENTION
[0002] The subject invention generally pertains to pliable air
ducts and more specifically to the air permeability of such a
duct.
DESCRIPTION OF RELATED ART
[0003] In HVAC systems (heating, ventilating, air conditioning),
conditioned supply air discharged from a blower is often conveyed
to various rooms or areas within a building by way of ductwork.
Conventional ductwork is typically formed of sheet metal and is
often installed above ceilings for convenience and aesthetics. But
in warehouses, manufacturing plants and many other buildings, the
ducts are suspended from the roof of the building and are thus
exposed. This not only creates a poor appearance in many cases, but
can create other problems as well.
[0004] For example, temperature differentials between an air duct
and the air on either side of the duct wall can create condensation
on both the interior and exterior of the duct. The presence of
condensed moisture on the interior of the duct may form mold or
bacteria that the duct then passes onto the room or other areas
being supplied with the conditioned air. If an exposed sheet metal
duct conveys relatively cool air, condensation can form on the
exterior of the duct. The condensate may then drip onto the floor,
inventory, and personnel below. The consequences of the dripping
can range anywhere from a minor irritation to a dangerously
slippery floor for the personnel, or complete destruction of the
products it may drip on (especially in food-processing
facilities).
[0005] Further, metal ducts with localized discharge registers have
been known to create uncomfortable drafts and unbalanced localized
heating or cooling within the building. In many food-processing
facilities where the target temperature is 42 degrees Fahrenheit, a
cold draft can be especially uncomfortable and perhaps
unhealthy.
[0006] Many of the above problems associated with exposed metal
ducts are overcome by the use of fabric ducts, such as DUCTSOX.TM.
fabric ducts by Frommelt Safety Products Corporation of Milwaukee,
Wis. Such ducts typically have a fabric wall that is air-permeable
to broadly and evenly disperse the air into the room being
conditioned or ventilated. If greater airflow in needed in certain
areas, the fabric duct can be provided with additional discharge
openings, such as air registers or cutouts in the fabric.
[0007] The porosity of conventional fabric can pass a substantial
amount of air, which can be desirable in many applications where
the airflow through the pores of the fabric is used primarily for
evenly dispersing air into a room. However, some applications
require airflow that is more directed toward certain areas of a
room. In such cases, it may be desirable to have relatively large
discharge openings provide most of the air airflow, while the pores
of the fabric provide only enough airflow to inhibit dust and
condensation from accumulating on the outer surface of the fabric
material.
[0008] Unfortunately, it can be difficult to acquire an air duct
material whose porosity provides an appropriately small amount of
airflow, such as 2 cfm (two cubic feet per minute of air across one
square-foot of material subject to a 0.02 psi air pressure
differential). Standard fabric materials have been found to pass 40
cfm or more. Such materials have been calendered in an attempt to
reduce the materials porosity. Although calendering conventional
fabric does reduce its porosity temporarily, much of the effect is
lost after the material is washed. Thus, simply calendering just
any porous fabric is not a permanent solution to the problem.
SUMMARY OF THE INVENTION
[0009] An air duct consists of an air permeable material that
passes air therethrough at a flow rate that is substantially less
than what the air duct discharges through other larger
openings.
[0010] In some embodiments, an air duct is made of a porous fabric
that is coated to reduce, but not eliminate, the fabric's
porosity.
[0011] In some embodiments, an air duct includes a pliable sheet
that includes a porous fabric base. The sheet is coated to render
the sheet substantially impermeable to air. The sheet is provided
with discharge openings for supplying air to a room, and is
perforated with much smaller openings that help inhibit the
formation of condensation or inhibit the accumulation of dust.
[0012] In some embodiments, an air duct with primary discharge
openings and much smaller pores or perforations is made of a fabric
with anti-microbial properties.
[0013] In some embodiments, an air duct is made of a coated porous
fabric that is calendered to reduce the fabric's porosity.
[0014] In some embodiments, the an air duct is made of a fabric
sheet having numerous minute pores or perforations that convey only
one to four CFM/ft.sup.2 (cubic feet per minute per square-foot of
material) when a 0.02 psia pressure differential exists across the
sheet.
[0015] In some embodiments, an air duct material is perforated by
displacing material rather than by removing a significant portion
of it. Displacing material not only helps reinforce the periphery
of each perforation, but also helps reduce the amount of scrap
during the perforating process.
[0016] In some embodiments, an air duct includes a fabric sheet
having a base material of polyester for strength and porosity, and
having an acrylic or polyurethane coating to reduce or eliminate
the base material's porosity.
[0017] In other examples, an air duct comprises a pliable sheet
configured to convey air, wherein the pliable sheet has a porosity
formed by an emorizing or sueding process, wherein the pliable
sheet includes a plurality of discharge openings that each provide
a first area and wherein the porosity of the pliable sheet provides
a plurality of second areas, with the first area being greater than
the second open area.
[0018] In some examples, an air duct, comprises a pliable sheet
configured to convey air, wherein the pliable sheet includes a
fabric base material that is porous and a coating on the fabric
base material that reduces the porosity of the fabric base material
yet leaves the pliable sheet porous, wherein the pliable sheet
includes a plurality of discharge openings that provide a first
open area and the porosity of the pliable sheet provides a second
open area with the first open area being greater than the second
open area.
[0019] In some yet other examples, a method of creating an air duct
comprises applying pressure to a pliable sheet having a porosity
below a desired porosity to increase the porosity of the pliable
sheet to the desired porosity; and configuring the pliable sheet to
convey air.
[0020] In some examples, a method of creating an air duct comprises
applying pressure to a pliable sheet to decrease a porosity of the
pliable sheet; after the application of the pressure, applying a
coating to the pliable sheet; and configuring the pliable sheet to
convey air.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a partial side view of one embodiment of a fabric
air duct that is able to inhibit at least some accumulation of dust
or condensate.
[0022] FIG. 2 is an enlarged view of the fabric used in the air
duct of FIG. 1, but with the fabric shown prior to it being
compressed.
[0023] FIG. 3 shows the fabric of FIG. 2, but after the fabric is
compressed to reduce its porosity.
[0024] FIG. 4 schematically illustrates a process of producing a
fabric air duct that is able to inhibit at least some accumulation
of dust or condensate.
[0025] FIG. 5 is a partial side view of another embodiment of a
fabric air duct that is able to inhibit at least some accumulation
of dust or condensate.
[0026] FIG. 6 is an enlarged view of the fabric used in the air
duct of FIG. 5, but with the fabric shown prior to it being
perforated.
[0027] FIG. 7 shows the fabric of FIG. 6, but after the fabric is
perforated.
[0028] FIG. 8 is a cross-sectional view taken along line 8-8 of
FIG. 7 while the fabric is being perforated.
[0029] FIG. 9 schematically illustrates a process of producing a
fabric air duct that is an alternative to that shown in FIG. 4 and
which may include an emorizing or sueding of a pliable sheet.
[0030] FIG. 10 is an enlarged view of the pliable sheet that may be
used in the process of FIG. 9.
[0031] FIGS. 11A and 11B are cross-sectional views of the pliable
sheet of FIG. 10 before and after an emorizing or sueding process,
respectively.
[0032] FIG. 12 is a view of a roller that may be used in a sueding
process to nap a pliable sheet.
[0033] FIG. 13 schematically illustrates a calendering process
alternative to that of FIG. 4, showing the calendering process
occurring before a coating process.
[0034] FIG. 14 is view of an air duct formed with a 1/4 round
cross-sectional profile.
[0035] FIG. 15 is a view of an air duct formed with a 1/2 round
cross-sectional profile.
[0036] FIG. 16 is a side view of an example air duct having a
non-uniform cross-sectional shape.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0037] An air duct 10, shown in FIG. 1, consists of a pliable sheet
12 in a tubular shape. Duct 10 is adapted to be suspended overhead
to convey forced air 14 from a blower to specific rooms or desired
areas within a building. Depending on the application, the air may
be for ventilation purposes only, or may be conditioned by heat,
cooling, filtering, humidifying, dehumidification, and various
combinations thereof.
[0038] Most of the air delivered to the rooms comes from discharge
openings 16 in duct 10, as indicated by airflow arrows 18. Openings
16 can assume a variety of forms including, but not limited to
cutouts, discharge registers, and screens.
[0039] To help inhibit condensation or dust from accumulating on
the surface of duct 10, the fabric wall between discharge openings
16 is provided with another set of much smaller openings 20.
Openings 20 allow the fabric wall of the duct to breathe in the
areas between discharge openings 16. A slight current of air 22
passing outward through the duct wall may help keep dust from
settling on the exterior of the duct. But also, when duct 10 is
conveying cool air, a small current of cool air passing through the
duct's fabric wall tends to keep the warmer room air slightly away
from the exterior surface of duct 10. Thus, moisture in the warmer
room air is less likely to condense on the surface of duct 10.
[0040] The actual size, number, and spacing of smaller openings 20
can vary; however, there does appear to be an optimum design range.
The relative open areas of openings 16 and 20 should allow about
ten percent (preferably less than more) of supply air 14 to pass
through smaller openings 20 and about ninety percent through
discharge openings 16. Sheet 12 should preferably pass one to four
CFM/ft.sup.2 with a 0.02-psi pressure differential across sheet 12
(i.e., 0.02 pounds per square inch of air pressure should force one
to four cubic feet of air across a one square-foot of sheet
material every minute). Higher airflow rates through smaller
openings 20 reduce the amount of air that discharge openings 16 can
direct to specific areas, while lower airflow rates are less
effective at reducing condensation or dust. In some cases, positive
results are achieved when openings 16 are able to pass more than
twenty times as much air as smaller openings 20. Moreover, the
distribution of openings 20 should be sufficiently dense to provide
an even flow of air through sheet 12. To avoid having smaller
openings 20 direct too much airflow in any particular direction,
openings 20 are preferably distributed over nearly the full
circumference or perimeter of duct 10.
[0041] To achieve appropriate airflow characteristics, sheet 12 may
consist of a fabric base material 24 with a coating 26 such as, for
example, a plastic coating, as shown in FIG. 2. In some
embodiments, fabric 24 is a porous woven material, such as
polyester. Coating 26, such as an acrylic or polyurethane coating,
is applied to fabric base 24 to reduce but not eliminate the
porosity of sheet 12. If the resulting openings 20' are too large,
as shown in FIG. 2, compressing or calendering sheet 12 can reduce
their size. Compressing sheet 12 forces coating 26 into openings
20' until the open area of openings 20' are reduced as indicated by
openings 20 of FIG. 3. Coating 26 tends to maintain the desired
size of openings 20' even after the material is washed.
[0042] The process of producing sheet 12 is schematically
illustrated in FIG. 4. Applying coating 26 is schematically
illustrated to encompass conventional coating processes that are
well known to those skilled in the art. Reducing the size of
openings 20' by compression can be achieved by a calendering
process where sheet 12 is compressed between two rollers 28 and 30.
In some cases, applying heat 32 to at least one of the rollers
softens coating 26, which may help in permanently reducing the size
of openings 20'. Once openings 20 are of an appropriate size, sheet
12 can be formed into a tubular shape 34. In some cases, coating 26
and/or fabric material 24 provides appreciable antimicrobial
properties as determined by standard tests, such as AATCC Method
100 (where AATCC stands for the American Association of Textile
Chemist and Colorists, of Research Triangle Park, N.C.). Coating 26
and/or fabric material 24 can also render sheet 12 flame retardant,
whereby sheet 12 is self-extinguishing.
[0043] In an alternate embodiment, shown in FIGS. 5-8, a duct 36
includes a pliable sheet 38 that may begin as a porous fabric base
material 40. The fabric base material 40 is then sealed with a
coating 26', such as for example a plastic coating, which
substantially eliminates the porosity of sheet 38, as shown in FIG.
6. To allow sheet 38 to breathe, a tool 42 perforates sheet 38 to
create numerous perforations 44 that are significantly smaller than
discharge openings 16', as shown in FIGS. 5 and 8. In some
embodiments, tool 42 is a needle that creates perforations 44 by
displacing material, rather than by just removing material. In this
way, built-up material 46 forms around the periphery of each
perforation 44, with the volume of material 46 being generally
equal to the void of each perforation 44. Such a process reduces
scrap and at the same time may avoid weakening a perforation's
circumference.
[0044] Just as with the embodiment of FIGS. 1-4, the size, number,
shape and spacing of perforations 44 of FIGS. 5-8 can vary.
However, in preferred embodiments, perforations 44 have an open
span 48 or effective diameter of less than 0.1 inches and are
distributed at a spacing 50 that is greater than a nominal
thickness 52 of sheet 38 but less than 0.5 inches. The term,
"effective diameter" equals the square-root of a hole's open area
times two and divided by the square-root of one divided by pi
(effective diameter=2(A/3.14).sup.0.5). In some cases, desirable
results may be achieved when the effective diameter of perforations
44 is less than thickness 52, and perforations 44 have a
distribution of 100 to 2000 perforations per square-inch.
[0045] A technique for producing a pliable sheet, alternative to
that shown in FIG. 4, is shown in FIG. 9. The technique applies
pressure to a pliable sheet 100, which may be porous or non-porous
prior to pressure application. The applied pressure may create
porosity in the pliable sheet 100 by an emorization process whereby
the outer surfaces of the pliable sheet 100 are abraded. For
example, the pliable sheet 100 may include an initially porous,
fabric base 102 treated with the coating 26 to completely remove
the porosity of the fabric base 102, as shown in FIG. 10. The
coating 26 may alternatively leave the coated pliable sheet 100
partially porous, similar to the illustrations in FIGS. 2 and
3.
[0046] The pliable sheet 100 is compressed between two rollers 104
and 106, which have abrasion surfaces, 108 and 110, respectively.
The abrasion surfaces 108, 110 have protrusions 112 compressing
against the surface of the pliable sheet 100 to create the desired
level of porosity. Thus, the process of FIG. 9 may form porosity in
a pliable sheet that has no porosity prior to the process, or it
may increase porosity in a pliable sheet that has a porosity below
a desired porosity. Desirable porosity levels may very and include
those described hereinabove.
[0047] FIG. 9 may also represent a sueding process, as described
below with respect to FIG. 12.
[0048] The abrasion surfaces 108 and 110 may be formed of sandpaper
or other rough surfaces, such as a surface coated with industrial
diamond particles. The protrusions 112 may be periodic or
aperiodic. In an example, the protrusions 112 cover the entire
surface 108 and 110.
[0049] FIG. 11A illustrates the pliable sheet 100, with the fabric
base layer 102 and coating layers 113a and 113b. The coating layers
113a and 113b result from application of the coating 26. The layer
113b represents a portion of the coating 26 that has diffused or
crept into the fabric base layer 102. The remaining layer 113a is
exposed on an outer surface of sheet 100. FIG. 11B illustrates the
pliable sheet 100 after it has been abraded by the rollers 104,
106. In the example of FIG. 11B, the layer 113a has been completely
removed by the emorizing or sueding process of FIG. 9, and the
fabric base layer 102 and the imbedded coating layer 113a create
the desired porosity. Alternatively, the emorizing or sueding
process may abrade the pliable sheet 100 to create porosity
therein--for example, if the pliable sheet 100 is non-porous or if
the porosity of the pliable sheet 100 is to be increased beyond
that of the its normal porosity.
[0050] Although the pliable sheet 100 is illustrated in FIG. 9 as
being exposed to a coating process that reduces the porosity of an
already porous sheet, this process is optional. The coating process
also may be eliminated, for example, when the pliable sheet 100 is
formed of flexible non-porous material. A further alternative
technique includes applying heat 116 to the rollers 104, 106, as
described above. Another technique includes abrading a single
surface of the sheet 100. Further still, the pliable sheet 100 may
be exposed to an additional porosity creating process, such as a
perforation process, either before or after compression. Indeed,
the emorizing process illustrated in FIG. 9 may be replaced with a
sueding or napping process by using a roller 120 (FIG. 12) having a
series of hooks or angled teeth 122 that may latch into a pliable
sheet during roller compression, where this latching may catch on
the pliable sheet and nap the surface thereof to create or increase
porosity. In any of these examples, the porous pliable sheet formed
by the rollers 104, 106 may be configured into a tubular pliable
sheet 124 to convey air. Preferably, the tubular pliable sheet 124
would include discharge openings, like the discharge openings 16 in
FIG. 1.
[0051] Another suitable process is a calendering process like that
of FIG. 4, but with the coating process coming after the
calendering process. FIG. 13 illustrates a pliable sheet 150 that
is compressed between two rollers 152 and 154. The sheet 150 may or
may not be porous. The rollers 152 and 154 calender the sheet 150
to reduce its porosity, for example. Heat 156 may be applied during
calendaring, as described above. After calendering, a coating is
applied by a wedge 158 that functions somewhat like a squeegee
evenly distributing the coating across the top surface of the sheet
150. By calendering first, the top surface of the pliable sheet 150
may be smoothened to allow for a more even application of the
coating. The calenderized sheet 150 is formed into a tubular
pliable sheet 160 in the illustrated example, although
alternatively it may be applied to another process, such as a
porosity-increasing process like that of FIG. 9 or a perforation
process. As with the tubular pliable sheet 124, in an example, the
tubular sheet 160 includes discharge openings.
[0052] While the tubular pliable sheets 124 and 160 are shown
having a uniform cross-sectional shape that is circular, the sheets
124 and 160 may be formed into other cross-sectional shapes and may
be uniform or non-uniform across their tubular length. FIGS. 14-16
show some such example air ducts. In FIG. 14, an air duct 200 is
formed having a first flat surface 202, a second flat surface 204,
and a curved surface 206, collectively forming a shape having a 1/4
round cross-section. The air duct 200 may be used, for example, as
a duct running along a corner formed by two orthogonal support
members, such as a wall and ceiling. The surfaces 202, 204, and 206
may all be porous surfaces formed through a perforation, emorizing,
sueding, or calenderization process. Alternatively, some of the
surfaces 202, 204, and 206 may have varying porosities including no
porosity. To flatten surface 202, the surface 202 is affixed to a
track 208, which may be sown in the duct 200 or mounted thereto,
for example, through a button, latch, glue, or VELCRO mounting. A
second track 210 is shown (in phantom) extending along wall 204. In
operation, the two tracks 208, 210 are mounted against orthogonal
support members, such as a wall and ceiling and the duct 200 takes
a 1/4 round shape. Screw or bolt fasteners may be used to mount to
the support member, for example. The duct 200 may include discharge
openings, not shown.
[0053] FIG. 15 shows a similar air duct in the form of 1/2 round
cross sectional air duct 300 having a top surface 302 and a curved
surface 304. The duct 300 may be formed by any of the techniques
described herein and may include two tracks 306, 308 that may be
mounted on a support member, such as a ceiling, to make the top
surface 302 taught a support 306 for a connector 308. The duct 300
may further include discharge openings, not shown.
[0054] FIGS. 14 and 15 show ducts with a uniform cross-sectional
area and shape over a tubular length. Alternatively, an air duct
may have a non-uniform area or shape. An example air duct 400 is
shown in FIG. 16. The air duct 400 has a tapered profile, where
discharge openings 402 and indentations 404, formed by the process
of FIGS. 9, 12, or 13, extend the length of a tapered region 406.
The tapered region 406 is capped by an end 408. The duct 400 is by
way of example only, however--the cross-sectional shape may change
across the tubular length of an duct, for example, by having a
circular shape at one cross-sectional position and a 1/4 round or
1/2 round shape at another. Other cross-sectional profiles may be
achieved.
[0055] Although the invention is described with reference to a
preferred embodiment, it should be appreciated by those of ordinary
skill in the art that various modifications are well within the
scope of the invention. For example, the pliable sheets described
herein do not have to include a fabric base. The sheets could
simply be a pliable air impermeable sheet, for example a plastic
sheet, which is perforated with micro-perforations or pinholes to
achieve desired flow characteristics. And in the case of the
emorizing and sueding techniques described with reference to FIGS.
9 and 12, as well as the calendering process of FIG. 13, the
pliable sheets fed to the pressuring step need not be porous at
all. Therefore, the scope of the invention is to be determined by
reference to the claims that follow.
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