U.S. patent application number 16/996361 was filed with the patent office on 2020-12-03 for methods, materials, and equipment to form improved fit duct liner insulation for round and oval hvac duct systems.
The applicant listed for this patent is JOHNS MANVILLE. Invention is credited to Eric Adamczyk, Thomas John Fellinger, Brennan Hall, Ames Kulprathipanja, Michaela Roxane Roy.
Application Number | 20200378646 16/996361 |
Document ID | / |
Family ID | 1000005022931 |
Filed Date | 2020-12-03 |
United States Patent
Application |
20200378646 |
Kind Code |
A1 |
Fellinger; Thomas John ; et
al. |
December 3, 2020 |
METHODS, MATERIALS, AND EQUIPMENT TO FORM IMPROVED FIT DUCT LINER
INSULATION FOR ROUND AND OVAL HVAC DUCT SYSTEMS
Abstract
The embodiments described herein relate generally to improved
fit duct liner insulation for curvilinear ducts in HVAC, exhaust,
or other similar gas flow systems. A duct liner insulation for a
curvilinear duct may include an insulation board having a first
major surface and a second major surface. The duct liner insulation
further includes a plurality of rows of kerfs in the first major
surface of the insulation board configured to allow the insulation
board to flex in a direction of the width of the insulation board
such that insulation board is foldable into a curvilinear
configuration. Each of the kerfs has a v-shaped cross section with
sidewalls extending from a kerf base portion at or near the second
major surface of the insulation board to the first major surface of
the insulation board. The sidewalls extending at an angle from 10
degrees to 20 degrees relative to each other.
Inventors: |
Fellinger; Thomas John;
(Littleton, CO) ; Roy; Michaela Roxane;
(Centennial, CO) ; Hall; Brennan; (Arvada, CO)
; Kulprathipanja; Ames; (Broomfield, CO) ;
Adamczyk; Eric; (Littleton, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
JOHNS MANVILLE |
Denver |
CO |
US |
|
|
Family ID: |
1000005022931 |
Appl. No.: |
16/996361 |
Filed: |
August 18, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
16013260 |
Jun 20, 2018 |
10782046 |
|
|
16996361 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F16L 59/147 20130101;
F24F 13/0263 20130101; B32B 2307/304 20130101; F16L 59/029
20130101; B32B 3/30 20130101; B32B 2597/00 20130101; B32B 2255/26
20130101; B32B 2307/7265 20130101; B32B 2255/205 20130101 |
International
Class: |
F24F 13/02 20060101
F24F013/02; F16L 59/02 20060101 F16L059/02; F16L 59/147 20060101
F16L059/147 |
Claims
1. A kerfing apparatus configured to kerf duct liner insulation for
a curvilinear duct, the kerfing apparatus comprising: at least one
of a tapered router bit operably coupled to a CNC milling machine
or a plurality of sets of stacked saw blades coupled to a rotatable
shaft, wherein each set of stacked saw blades of the plurality of
sets of stacked saw blades comprises an odd number of saw blades;
and wherein the at least one of the tapered router bit or the
plurality of sets of stacked saw blades are configured to cut a
plurality of rows of kerfs having v-shaped cross sectional
configurations in an insulation board, the rows of kerfs configured
to allow the insulation board to flex in a direction of the width
of the insulation board such that insulation board is foldable into
a curvilinear configuration to line the curvilinear duct when
installed, and each of the kerfs of the plurality of rows of kerfs
having sidewalls extending from a kerf base portion at or near a
second major surface of the insulation board to a first major
surface of the insulation board, the sidewalls extending at an
angle from 10 degrees to 20 degrees relative to each other
2. The kerfing apparatus of claim 1 wherein each set of stacked saw
blades comprises at least three saw blades including a first saw
blade with second and third saw blades stacked on opposing sides of
the first saw blade, wherein the first saw blade has a diameter
greater than diameters of the second and third saw blades, and
wherein diameters of the second and third saw blades are equal.
3. The kerfing apparatus of claim 1 wherein a smallest diameter saw
blade of each set of the stacked saw blades is at least 1 inch
greater in diameter than a diameter of the rotatable shaft
4. The kerfing apparatus of claim 1, further comprising one or more
spacers coupled to the rotatable shaft between at least two sets of
stacked saw blades, wherein the curvilinear duct comprises a flat
oval duct with flat portions and round portions, and wherein the
one or more spacers have widths substantially equal to a width of
the flat portions of the curvilinear duct.
5. A method of kerfing duct liner insulation for a curvilinear
duct, the method comprising: cutting a plurality of rows of kerfs
having v-shaped cross sectional configurations in an insulation
board, the rows of kerfs configured to allow the insulation board
to flex in a direction of the width of the insulation board such
that insulation board is foldable into a curvilinear configuration
to line the curvilinear duct when installed, and each of the kerfs
of the plurality of rows of kerfs having sidewalls extending from a
kerf base portion at or near a second major surface of the
insulation board to a first major surface of the insulation board,
the sidewalls extending at an angle from 10 degrees to 20 degrees
relative to each other.
6. The method of kerfing duct liner insulation of claim 5, further
comprising cutting the plurality of rows of kerfs with at least one
tapered router bit operably coupled to a CNC milling machine.
7. The method of kerfing duct liner insulation of claim 5, further
comprising cutting the plurality of rows of kerfs with a
corresponding plurality of sets of stacked saw blades coupled to a
rotatable shaft, wherein each set of stacked saw blades of the
plurality of sets of stacked saw blades comprises an odd number of
saw blades.
8. The method of kerfing duct liner insulation of claim 7, wherein
each set of stacked saw blades comprises at least three saw blades
including a first saw blade with second and third saw blades
stacked on opposing sides of the first saw blade, wherein the first
saw blade has a diameter greater than diameters of the second and
third saw blades, and wherein diameters of the second and third saw
blades are equal.
9. The method of kerfing duct liner insulation of claim 7, wherein
a smallest diameter saw blade of each set of the stacked saw blades
is at least 1 inch greater in diameter than a diameter of the
rotatable shaft.
10. The method of kerfing duct liner insulation of claim 5, wherein
cutting the plurality of rows of kerfs includes cutting a first row
of kerfs such that first and second kerfed segments are formed on
each side of the first row of kerfs, the first and second kerfed
segments having trapezoidal cross sectional configurations, and
wherein each of the first and second kerfed segments have an upper
base width (a) and a lower base width (b).
11. The method of kerfing duct liner insulation of claim 10,
wherein one or more spacers are coupled to the rotatable shaft
between at least two sets of stacked saw blades, the one or more
spacers having a width substantially equal to the upper base width
(a).
12. The method of kerfing duct liner insulation of claim 10,
wherein the lower base width (b) ranges from 0.6 inches to 1.6
inches.
13. The method of kerfing duct liner insulation of claim 10,
wherein the lower base width (b) ranges from 0.6 inches to 1.0
inches.
14. The method of kerfing duct liner insulation of claim 5, wherein
the sidewalls extend at an angle from 13 degrees to 17 degrees
relative to each other.
15. The method of kerfing duct liner insulation of claim 5, wherein
the sidewalls extend at an angle from 14 degrees to 16 degrees
relative to each other.
16. The method of kerfing duct liner insulation of claim 5, wherein
a depth of each of the kerfs does not penetrate the second major
surface.
17. The method of kerfing duct liner insulation of claim 5, wherein
the curvilinear duct comprises a flat oval duct with flat portions
and round portions and the insulation board comprises kerfed
segments and unkerfed segments, the kerfed segments configured to
line the round portions of the flat oval duct and the unkerfed
segments configured to line flat portions of the flat oval duct
when the insulation board is installed within the curvilinear
duct.
18. The method of kerfing duct liner insulation of claim 17,
wherein one or more spacers are coupled to the rotatable shaft
between at least two sets of stacked saw blades, the one or more
spacers having a width substantially equal to a width of the flat
portions of the curvilinear duct.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a division of prior pending U.S.
application Ser. No. 16/013,260 filed Jun. 20, 2018. The entire
contents of the above-identified application is herein incorporated
by reference for all purposes.
BACKGROUND OF THE INVENTION
[0002] The present disclosure relates generally to duct liner
insulation products for curvilinear ducts, and more specifically
relates to methods, materials, and equipment to form improved fit
duct liner insulation for round or oval ducts in, for example,
heating, ventilating, and air conditioning (HVAC) systems. HVAC,
exhaust, and other similar gas flow systems commonly found in a
building structure may require insulated curvilinear (e.g., round
or flat oval) air ducts for conveying conditioned air from air
handling units to locations throughout the building structure, for
returning air to the air handling units for heating, cooling, or
recirculation, or for conveying other gases such as exhaust gases.
Ducts of such systems are generally lined with rigid or semi-rigid
duct liner insulation. Such duct liner insulation may control or
attenuate acoustical or thermal transmissions within and through
the systems to reduce transmitted noise and conserve energy.
[0003] A current industry solution for insulating curvilinear
(e.g., round or oval) ducts includes lining such ducts with rigid
or semi-rigid insulation board liners which have rows of parallel
kerfs (e.g., grooves) extending along their gas stream surfaces.
The kerfs allow the insulation board liners to be curved or bent
about an axis parallel to the kerfs into tubular shapes to line
such curvilinear ducts. However, difficulty remains in properly
fitting the insulation liners to ducts of particular curvilinear
cross sections or sizes such that the liners conform properly or
extend in a substantial uniform manner around the inner periphery
of the ducts. For example, potential delamination, gap, and fit
issues or issues with bending the insulation board (e.g.,
difficulty in bending) may arise. Openings or gaps between kerfs
after installation within the ducts may expose uncoated fibers to
the gas stream which may dislodge such fibers as air or other gases
flow therethrough. Additionally, in relatively small diameter
curvilinear ducts (e.g., 10 inches or smaller, 12 inches or
smaller), the kerfed insulation board liners may have an undesired
"blocky" appearance when installed. In flat oval ducts, sagging of
such insulation from the upper flat portion of such flat oval
ducts, as well as exposed uncoated fibers to the gas stream may
arise from liners with continuous kerfing. Further, gaps between
kerfs or delamination of insulation materials may occur, if for
example, the insulation board liner is bent too aggressively to
close such gaps to line the flat oval duct. Therefore, there
remains a need for methods, materials, and equipment to form
improved fit (e.g., uniform, conformity) duct liner insulation for
curvilinear ducts including round or flat oval ducts. In
particular, there remains a need for improved fit duct liner
insulation for small diameter round or flat oval ducts that are
less costly to manufacture or install, or reduce or prevent
potential delamination, sagging, gap, or fit issues (e.g., blocky
appearance, uniform or conformity issues) or issues with bending
the insulation board.
BRIEF SUMMARY OF THE INVENTION
[0004] The embodiments described herein relate generally to duct
liner insulation products for curvilinear ducts, and more
specifically relate to methods, materials, and equipment to form
improved fit duct liner insulation for round or oval ducts in HVAC,
exhaust, or other similar gas flow systems. In particular, certain
embodiments of the duct liner insulation may include kerfed duct
liner insulation with improved conformity or uniformity in lining
or fitting small diameter (e.g., 10 inches or less or 12 inches or
less) curvilinear ducts (e.g., round or oval ducts). In other
embodiments, duct liner insulation may include segments or sections
with and without kerfing for flat oval ducts. The methods,
materials, and equipment described herein may provide improved fit
duct liner insulation for round or flat oval ducts. For example,
improved duct liner insulation as described herein may reduce or
prevent potential delamination, gap, and fit issues (e.g., uniform
or conformity issues) or issues with bending the insulation that
may arise with other kerfed insulation products. The duct liner
insulation described herein may provide a less "blocky" appearance
by improving conformity with an inner periphery of a small diameter
curvilinear duct when installed. In certain embodiments, the duct
liner insulation with segments or sections with and without kerfing
described herein may be less susceptible to sagging, exposed
fibers, kerf gaps, or delamination when installed within flat oval
ducts.
[0005] According to a first aspect, a duct liner insulation for a
curvilinear duct is provided that includes an insulation board
having a first major surface and a second major surface, wherein
the first major surface is configured to be a gas stream surface
and the second major surface is configured to extend around an
inner periphery of a curvilinear duct when the insulation board is
installed within the curvilinear duct. The insulation board has a
length, width, and thickness. The duct liner insulation further
includes a plurality of rows of kerfs in the first major surface of
the insulation board configured to allow the insulation board to
flex in a direction of the width of the insulation board such that
insulation board is foldable into a curvilinear configuration. The
insulation board has a cross sectional configuration substantially
mirroring a cross sectional configuration of the inner periphery of
the curvilinear duct when installed. Each of the kerfs has a
v-shaped cross section with sidewalls extending from a kerf base
portion at or near the second major surface of the insulation board
to the first major surface of the insulation board, the sidewalls
extending at an angle from 10 degrees to 20 degrees relative to
each other.
[0006] In some embodiments, a first row of kerfs of the plurality
of rows of kerfs is formed between first and second kerfed
segments, the first and second kerfed segments having trapezoidal
cross sectional configurations. Each of the first and second kerfed
segments having an upper base width (a) and a lower base width (b).
The lower base width (b) may range from 0.6 inches to 1.6 inches.
The lower base width (b) may range from 0.6 inches to 1.0 inches.
The sidewalls may extend at an angle from 13 degrees to 17 degrees
relative to each other. The sidewalls may extend at an angle from
14 degrees to 16 degrees relative to each other.
[0007] In some embodiments, the first major surface or the second
major surface include a facing. The thickness of the insulation
board may range from 1 inches to 3 inches. In certain embodiments,
a depth of the kerfs does not penetrate the second major surface.
In some embodiments, the curvilinear duct is a round duct. The
round duct may have a diameter from 6 inches to 12 inches.
[0008] In some embodiments, the curvilinear duct is a flat oval
duct. The flat oval duct may have a height from 6 inches to 12
inches. In certain embodiments, the insulation board may include
both kerfed segments and unkerfed segments. The kerfed segments are
configured to line round portions of the flat oval duct and the
unkerfed segments are configured to line flat portions of the flat
oval duct when the insulation board is installed. The kerfed and
unkerfed segments may be monolithically formed. In other
embodiments, the kerfed and unkerfed segments are separately formed
and configured to be joined together to be installed within the
flat oval duct.
[0009] According to another aspect, a kerfing apparatus configured
to kerf duct liner insulation for a curvilinear duct is provided.
The kerfing apparatus includes at least one of a tapered router bit
operably coupled to a CNC milling machine or a plurality of sets of
stacked saw blades coupled to a rotatable shaft. Each set of
stacked saw blades of the plurality of sets of stacked saw blades
includes an odd number of saw blades. The at least one of the
tapered router bit or the plurality of sets of stacked saw blades
are configured to cut a plurality of rows of kerfs having v-shaped
cross sectional configurations in an insulation board. The rows of
kerfs are configured to allow the insulation board to flex in a
direction of the width of the insulation board such that insulation
board is foldable into a curvilinear configuration to line the
curvilinear duct when installed. Each of the kerfs of the plurality
of rows of kerfs have sidewalls extending from a kerf base portion
at or near a second major surface of the insulation board to a
first major surface of the insulation board. The sidewalls extend
at an angle from 10 degrees to 20 degrees relative to each
other
[0010] In certain embodiments, each set of stacked saw blades
includes at least three saw blades including a first saw blade with
second and third saw blades stacked on opposing sides of the first
saw blade. The first saw blade has a diameter greater than
diameters of the second and third saw blades. The diameters of the
second and third saw blades are equal.
[0011] In certain embodiments, a smallest diameter saw blade of
each set of the stacked saw blades is at least 1 inch greater in
diameter than a diameter of the rotatable shaft. In some
embodiments, the kerfing apparatus further includes one or more
spacers coupled to the rotatable shaft between at least two sets of
stacked saw blades. The curvilinear duct includes a flat oval duct
with flat portions and round portions, and the one or more spacers
have widths substantially equal to a width of the flat portions of
the flat oval duct.
[0012] According to another aspect, a method of kerfing duct liner
insulation for a curvilinear duct is provided. The method includes
cutting a plurality of rows of kerfs having v-shaped cross
sectional configurations in an insulation board, the rows of kerfs
configured to allow the insulation board to flex in a direction of
the width of the insulation board such that insulation board is
foldable into a curvilinear configuration to line the curvilinear
duct when installed. Each of the kerfs of the plurality of rows of
kerfs have sidewalls extending from a kerf base portion at or near
a second major surface of the insulation board to a first major
surface of the insulation board, the sidewalls extending at an
angle from 10 degrees to 20 degrees relative to each other.
[0013] In some embodiments, the method further includes cutting the
plurality of rows of kerfs with at least one tapered router bit
operably coupled to a CNC milling machine. In other embodiments,
the method further includes cutting the plurality of rows of kerfs
with a corresponding plurality of sets of stacked saw blades
coupled to a rotatable shaft, wherein each set of stacked saw
blades of the plurality of sets of stacked saw blades includes an
odd number of saw blades. Each set of stacked saw blades may
include at least three saw blades including a first saw blade with
second and third saw blades stacked on opposing sides of the first
saw blade. The first saw blade has a diameter greater than
diameters of the second and third saw blades, and diameters of the
second and third saw blades are equal. A smallest diameter saw
blade of each set of the stacked saw blades is at least 1 inch
greater in diameter than a diameter of the rotatable shaft.
[0014] In some embodiments, cutting the plurality of rows of kerfs
includes cutting a first row of kerfs such that first and second
kerfed segments are formed on each side of the first row of kerfs.
The first and second kerfed segments have trapezoidal cross
sectional configurations, and wherein each of the first and second
kerfed segments have an upper base width (a) and a lower base width
(b). In some embodiments, one or more spacers are coupled to the
rotatable shaft between at least two sets of stacked saw blades,
the one or more spacers having a width substantially equal to the
upper base width (a). The lower base width (b) may range from 0.6
inches to 1.6 inches. The lower base width (b) may range from 0.6
inches to 1.0 inches.
[0015] In some embodiments, the sidewalls extend at an angle from
13 degrees to 17 degrees relative to each other. In other
embodiments, the sidewalls extend at an angle from 14 degrees to 16
degrees relative to each other. In certain embodiments, a depth of
each of the kerfs does not penetrate the second major surface.
[0016] In some embodiments, the curvilinear duct is a flat oval
duct with flat portions and round portions and the insulation board
comprises kerfed segments and unkerfed segments. The kerfed
segments are configured to line the round portions of the flat oval
duct and the unkerfed segments are configured to line flat portions
of the flat oval duct when the insulation board is installed within
the curvilinear duct. One or more spacers may be coupled to the
rotatable shaft between at least two sets of stacked saw blades,
the one or more spacers having a width substantially equal to a
width of the flat portions of the curvilinear duct.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective view of an insulation board for duct
liner insulation with a kerfed gas stream surface in accordance
with an exemplary embodiment of the present disclosure.
[0018] FIG. 2 illustrates duct liner insulation with a round cross
sectional configuration formed from the kerfed insulation board of
FIG. 1 in accordance with an exemplary embodiment of the present
disclosure.
[0019] FIG. 3 illustrates the duct liner insulation of FIG. 2
installed within a round duct in accordance with exemplary
embodiments of the present disclosure.
[0020] FIG. 4 illustrates duct liner insulation with a flat oval
cross sectional configuration formed from the kerfed insulation
board of FIG. 1 in accordance with another exemplary embodiment of
the present disclosure.
[0021] FIG. 5 illustrates the duct liner insulation of FIG. 4
installed within a flat oval duct in accordance with exemplary
embodiments of the present disclosure
[0022] FIG. 6A is a close up view of a portion of a v-shaped kerf
and kerfed segments of the insulation board of FIG. 1 and FIG. 6B
is a close up view of the portion of the v-shaped kerf and kerfed
segments of the insulation board of FIG. 1 when the duct liner
insulation board is formed into a curvilinear shaped in accordance
with an exemplary embodiment of the present disclosure.
[0023] FIG. 7A is a close up view of a portion of a substantially
v-shaped kerf and kerfed segments of the insulation board of FIG. 1
and FIG. 7B is a close up view of the portion of the substantially
v-shaped kerf and kerfed segments of the insulation board of FIG. 1
when the duct liner insulation board is formed into a curvilinear
shaped in accordance with another exemplary embodiment of the
present disclosure.
[0024] FIGS. 8A-8D are various views of an improved kerfed
insulation board for fitting a round duct in accordance with an
exemplary embodiment of the present disclosure.
[0025] FIGS. 9A-9D are various views of an improved kerfed
insulation board for fitting a flat oval duct in accordance with
another exemplary embodiment of the present disclosure.
[0026] FIG. 10 is a side view of a tapered router bit for kerfing
insulation boards in accordance with an exemplary embodiment of the
present disclosure.
[0027] FIGS. 11A-11B are front and side views, respectively, of a
portion of a stacked circular saw blade apparatus for kerfing
insulation boards in accordance with another exemplary embodiment
of the present disclosure.
[0028] FIGS. 12A-12B are front and side views, respectively, the
stacked circular saw blade apparatus of FIGS. 11A-11B with a keyed
rotatable shaft in accordance with another exemplary embodiment of
the present disclosure.
[0029] FIGS. 13A-13B are cross sectional views of a duct liner
insulation for a flat oval duct with separately formed kerfed and
unkerfed segments prior to and after being coupled in accordance
with an exemplary embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The ensuing description provides exemplary embodiments only,
and is not intended to limit the scope, applicability or
configuration of the disclosure. Rather, the ensuing description of
the exemplary embodiments will provide those skilled in the art
with an enabling description for implementing one or more exemplary
embodiments. It being understood that various changes may be made
in the function and arrangement of elements without departing from
the spirit and scope of the invention as set forth in the appended
claims.
[0031] "ASTM" refers to American Society for Testing and Materials
and is used to identify a test method by number. The year of the
test method is either identified by suffix following the test
number or is the most recent test method prior to the priority date
of this document.
[0032] The embodiments described herein and illustrated in FIGS.
1-13B relate generally to duct liner insulation products for
curvilinear ducts, and more specifically relate to methods,
materials, and equipment to form improved fit duct liner insulation
for round or oval ducts in HVAC, exhaust, or other similar gas flow
systems. With reference to FIGS. 1-5, a duct liner insulation 10 as
described herein includes an insulation board 20. The duct liner
insulation 10 may also be configured as a blanket, mat, batt,
sheet, or roll. The duct liner insulation 10 may be installed
within (e.g., line) a curvilinear duct, for example, a round duct
40 (FIG. 3) or a flat oval duct 42 (FIG. 5). The insulation board
20 may be semi-rigid or rigid insulation board made of fibrous
material, cellular foam, mineral wool, or a composite of such
materials. The insulation board 20 may have a rectangular cross
sectional configuration when in an unfolded, unbent, or uninstalled
configuration as illustrated in FIG. 1. In other embodiments, the
insulation board may have another suitable cross sectional
configuration. The insulation board 20 mirrors or has substantially
the same cross sectional configuration as the curvilinear duct when
lining the curvilinear duct in the folded, bent, or installed
configuration (e.g., round or circular in FIG. 3 and flat oval in
FIG. 5).
[0033] The insulation board 20 includes a first major surface 22
(e.g., top surface) which is a gas stream or interior surface and a
second major surface 24 (e.g., bottom surface) which is an outside
surface. In certain embodiments, the gas stream surface 22 of the
insulation board may be untreated as an additional cost savings.
However, in other embodiments, the gas stream surface 22 has a
coating or facing 26 covering the gas stream surface, such as but
not limited to, a polymeric coating, a non-combustible foil facing,
a synthetic polymer film, a metallic foil composite or a treated,
non-woven mat (e.g. a polyester mat coated with a polymeric
coating). The outside surface 24 of the insulation board 20 may be
provided with a moisture barrier facing 28, such as but not limited
to a foil-scrim-kraft facing.
[0034] As shown in FIG. 1, the gas stream surface 22 of the
insulation board 20 is provided with a plurality of kerfs 30 (e.g.,
rows of kerfs 30). The kerfs 30 (e.g., grooves, openings) extend
the length of the insulation board and are spaced and extend
parallel with respect to each other. In other embodiments, the
kerfs 30 may extend the width of the insulation board and are
spaced and extend parallel with respect to each other. The kerfing
of the insulation board 20 forms a plurality of longitudinally
extending kerfed segments 32 which are hinged together by the hinge
portions 34 of the insulation boards intermediate the bottoms of
the kerfs 30 and the outside surfaces 24 of the insulation boards
plus the facings 28 on the outside surfaces of the insulation
boards. Preferably, the bottom of the kerfs 30 are at or proximate
the bottom of the outside surface 24 (e.g., without penetrating the
outside surface or extending into the facing 28) such that the
hinge portions 34 are relatively small. For example, bottoms of the
kerfs may be positioned from or extend to within 1/16'' to 1/8'' of
the bottom of the outside surface 24. In this manner, the kerfs 30
extend through substantially the entire thickness of the insulation
board 20. Depths of the kerfs 30 may range from 85% to 95% of the
thickness of the insulation board 20. Thus, for a 2 inch thick
insulation board as an example, the hinge portions 34 may range
from 0.1 inches to 0.3 inches in depth. In other embodiments,
depths of the kerfs 30 may be up to 91%, 92%, 93%, 94%, 95%, 96%,
97%, 98%, or 99%, or any value therebetween of the thickness of the
insulation board 20. In some embodiments, the depths of the kerfs
30 may be greater than 90% of the thickness of the insulation board
20 but less than 100%. As used herein, the dimension of the
insulation board 20 parallel to the kerfs is defined as the length
of the insulation board 20 and the dimension of the insulation
board perpendicular to the kerfs is defined as the width of the
insulation boards. Preferably, the kerfs 30 are formed with desired
dimensions by a plurality of appropriately spaced and driven
tapered end mill bits or sets of stacked steel, ceramic or carbide
saw blades of various diameters as described in more detail below
with respect to FIGS. 10-12B.
[0035] The kerfing of the insulation board 20 allows the insulation
board to be folded, bent, or curved in the direction of its width
(e.g., when the kerfs 30 extend along the length of the insulation
board) to enable the insulation board to be formed into the
curvilinear shape of a duct to line the duct. In other embodiments,
the kerfing allows the insulation board to be folded, bent, or
curved in the direction of its length (e.g., when the kerfs 30
extend along the width of the insulation board). The kerfs 30
cannot be placed too close together (e.g., with kerfs 30 too wide
or kerfed segments 32 too narrow) or the insulation material of the
insulation board in the longitudinal kerfed segments 32 may lose
its integrity or the insulation board 20 may fall apart. Further,
if the kerfs 30 are too wide, gaps may result when the insulation
board is installed exposing fibers or other particles to the gas
stream. If the kerfs 30 are spaced too far apart (e.g., with kerfs
30 too narrow or kerfed segments 32 too wide), the insulation board
20 may not have the flexibility in the direction of its width to
enable the insulation board to be bent and curved into a
curvilinear shape of the desired dimensions when installed (e.g.,
may appear block-like). Therefore, as described in more detail
below (FIGS. 8A-9D), size or dimensions (e.g., depth, thickness,
width, length), spacing, angle, or number of kerfs 30 or kerfed
segments 32 may be pre-selected or determined to improve fit (e.g.,
conformity or uniformity) within a curvilinear duct or reduce or
eliminate potential delamination, kerf gap, sagging, or other fit
issues or issues with bending the insulation board 20. In
particular, kerfing of the duct liner insulation 10 may be improved
for small diameter (e.g., 10 inches or less) round ducts or flat
oval ducts.
[0036] As shown in FIGS. 2 and 4, after the insulation board 20 has
been formed (e.g., bent, folded, curved) into a round and flat oval
duct liners, respectively, the lateral edges of the insulation
board may be secured together with tape 37, glue, or other suitable
fasteners or adhesives so that the insulation board will remain in
its curvilinear (e.g., round or flat oval) cross sectional
configuration. The insulation board 20 may then be inserted into
the round or flat oval ducts 40 or 42 to form the duct liner
insulation 10, as illustrated in FIGS. 3 and 5, respectively. The
insulation board 20 may be further adhered to the ducts when
installed (e.g., with glue or other adhesive) once installed in
certain embodiments. The round and flat oval ducts 40 and 42 used
in the present invention are typically conventional tubular shells
commonly used for industrial and commercial applications. The round
or flat oval ducts 40 and 42 are typically made of spirally wound
sheet metal strips with adjacent convolutions of the metal strips
joined by a conventional spiral seam. Multiple ducts may be joined
together by male/female connectors; sleeves; or outer flanges, such
as the flanges 48 and 50 shown in FIGS. 3 and 5; or other
conventional means.
[0037] As shown in FIGS. 6A and 6B, each of the kerfs 30 may have
v-shaped transverse cross sections with sidewalls 74 and 76 which
meet at the base or bottom of the kerf 30 and extend to the gas
stream surface of the insulation board 20. The sidewalls diverge
with respect to each other and a plane 78, extending perpendicular
to the gas stream surface 22 of the insulation board 20 and
bisecting the kerf 30 along a longitudinal centerline of the kerf
30, from the base of the kerf 30 to the gas stream surface 22 of
the insulation board 20. The kerf 30 has shoulders 79 adjoining the
gas stream surface 22 of the insulation board 20. When the
insulation board 20 is folded, bent, or formed into a curvilinear
configuration to form a duct liner as shown in FIG. 6A, the
shoulders 79 of the kerf 30, adjoining the gas stream surface 22 of
the insulation board 20, come together (e.g., abut) and the
sidewalls 74 and 76 abut along their surfaces so that no or
substantially no air space is formed in the wall of the duct liner
insulation 10. The widths of the openings of the kerfs 30 of the
present invention may be defined by a pair of planes 90 and 92
which extend from a common vertex point 94 (e.g., at
non-perpendicular angles relative to the first and second major
surfaces), located at or proximate the second major surface 24 of
insulation board in the plane 78 bisecting the kerf 30 through the
junctures of the kerf sidewalls with the gas stream surface 22, as
shown in FIGS. 6A and 7A. Preferably, as discussed above, the base
of the kerfs 30 is positioned at or proximate to the point 94
(e.g., such that the kerfs 30 do not extend into the facing 28 or
penetrate through the second major surface 24). As described in
more detail below (FIGS. 8A-9D), in some embodiments, the included
angle .theta. between the sidewalls or planes may be selected, or
have a value within a range for improved fitting or lining of a
curvilinear duct.
[0038] In some embodiments, the kerfs 30 are formed so that the
shoulders 79 not only abut when the insulation board 20 is bent
into a desired curvilinear configuration of preselected dimensions,
but the shoulders are pressed together, when the insulation board
has been formed into the desired curvilinear configuration, with
sufficient force to compress the insulation material in the
shoulders 79 so that the curvilinear configuration of the duct
liner insulation formed from the insulation board 20 is retained
after the insulation board has been formed into the duct liner
(FIGS. 2 and 4) or installed within the ducts (FIGS. 3 and 5). The
kerfs 30 are formed so that the insulation material in the
sidewalls, for the entire or substantially the entire depth of the
kerf, are subjected to compression when the insulation board 20 is
bent into the curvilinear cross sectional configuration of the
preselected dimensions to further rigidify the duct liner formed
from the insulation board 20.
[0039] In other embodiments, as shown in FIGS. 7A and 7B, each of
the kerfs 30 may have v-shaped transverse cross sections with
sidewalls 80 and 82 which extend from a base or bottom of the kerf
30 to the gas stream surface 22 of the insulation board 20, similar
to the kerfs illustrated in FIGS. 6A-6B. However, the sidewalls 80
and 82 of kerf 30 do not meet at the base of the kerf. Instead the
sidewalls 80 and 82 are narrowly spaced from each other at the base
of the kerf 30 and diverge with respect to each other and a plane
84, extending perpendicular to the gas stream surface 22 of the
insulation board 20 and bisecting the kerf 30 along the
longitudinal centerline of the kerf 30, from the base of the kerf
30 to the gas stream surface 22 of the insulation board 20. The
kerf 30 has shoulders 85 adjoining the gas stream surface 22 of the
insulation board. When the insulation board 20 is bent or formed
into a curvilinear configuration to form a duct liner as shown in
FIG. 7A, the shoulders 85 of the kerf, adjoining the gas stream
surface 22 of the insulation board 20, come together and a very
narrow air space 86 is formed in the wall of the duct or duct liner
at the bottom of the kerf 30.
[0040] As noted above, one or more of size or dimensions (e.g.,
depth, thickness, width, length), spacing, angle, or number of
kerfs 30 or kerfed segments 32 may be pre-selected or determined to
improve fit within a curvilinear duct or reduce or eliminate
potential delamination, kerf gap, or fit issues or issues with
bending the insulation board 20. In particular, kerfing of the duct
liner insulation 10 may be improved for better fitting or lining
small diameter (e.g., 10 inches or less or 12 inches or less)
curvilinear ducts. For example, kerfing of liners may be improved
for 6-12 inch (e.g., 6, 8, 10, or 12 inch) diameter curvilinear
ducts as described herein. In other embodiments, improved kerfing
may be provided for curvilinear ducts having diameters of 12 inches
or more (e.g., 12 inches, 14 inches, 16 inches, 18 inches, 20
inches, up to 30 inches, up to 100 inches).
[0041] With reference to FIGS. 8A-9D, kerfing of the duct liner
insulation 10 may be improved for curvilinear ducts, and in
particular, small diameter round ducts (FIGS. 8A-8D) or flat oval
ducts (FIGS. 9A-9D). In some embodiments, at least one of the width
(e.g., bottom or top widths--(b), (a)) of the kerfed segments 32,
number (n) of kerfed segments 32, thickness (Thk), outer diameter
(D) or outer circumference (L1), width (c) of kerfs 30, or the
angle .theta. between the two planes of the openings of kerfs 30 of
the insulation board 20 may be selected or pre-determined to
improve fit of the duct liner insulation 10 for a curvilinear duct
such that the insulation 10 conforms better to the inner periphery
of the duct or extends in a more substantially uniform manner. For
example, the number (n) of kerfed segments 32 may be
pre-determined, adjusted, specified, or selected based on or for an
insulation board 20 with a set or given thickness (Thk) and outer
diameter (D) or outer circumference (L1) such that the angle
.theta. between the two planes of the openings of kerfs 30 or the
bottom width (b) of the kerfed segments 32 are within ranges to
better or improve fit (e.g., conformity or uniformity) within a
round duct as described in more detail below.
[0042] In other embodiments, the thickness (Thk) may be
pre-determined, adjusted, specified, or selected based on or for an
insulation board 20 with a set or given number (n) of kerfed
segments 32 and outer diameter (D) or outer circumference (L1) such
that the angle .theta. between the two planes of the openings of
kerfs 30 and the bottom width (b) of the kerfed segments 32 are
within ranges for improved fitting or lining of a round duct. In
yet further embodiments, outer diameter (D) or outer circumference
(L1) may be pre-determined, adjusted, specified, or selected based
on or for an insulation board 20 with a set or given thickness
(Thk) and number (n) of kerfed segments 32 such that the angle
.theta. between the two planes of the openings of kerfs 30 and the
bottom width (b) of the kerfed segments 32 are within ranges for
improved fitting or lining of a round duct. Therefore, when two of
three variables of, for example: number of kerfed segments 32,
thickness (Thk), and outer diameter (D) or outer circumference (L1)
are fixed, set, or known depending on a diameter of the duct to be
lined, the other or third variable may be adjusted, selected, or
determined such that the angle .theta. between the two planes of
the openings of kerfs 30 or the bottom width (b) of the kerfed
segments 32 are within ranges to provide improved fitting or lining
of the duct.
[0043] Typically, the insulation board 20 for duct liner insulation
10 as described herein has a thickness (Thk) ranging from 1 inch to
4 inches (e.g., in increments of a % inch). The insulation board 20
may have a thickness (Thk) in a range of 0.5 inches to 3.0 inches,
0.5 inches to 2.5 inches, 0.5 inches to 2 inches, 1 inch to 3
inches, 1 inch to 2.5 inches, or 1 inch to 2 inches, or any value
therebetween. An insulation board 20 with a desired thickness may
be selected depending on the application or insulating properties.
The outer diameter (D) or outer circumference (L1) of the
insulation board 20 generally mirrors or is substantially equal to
that of the inner diameter or circumference of the round duct to be
fitted or lined. The outer circumference (L1) or width of the
insulation board 20 required (e.g., to be cut) may then be
determined based on the outer diameter (D) of the insulation board
(e.g., inner diameter or circumference of the round duct to be
fitted or lined). Therefore, for small round ducts, the outer
diameter (D) may range or be selected within a range, for example,
from 6 inches to 10 inches depending on the inner diameter of the
duct to be lined and the width or outer circumference (L1) of the
insulation board 20 required may be determined accordingly. For
improving fit or conformity within a round duct, the angle .theta.
between the two planes of the openings of kerfs 30 typically ranges
from 10.degree. to 20.degree., 11.degree. to 19.degree., 12.degree.
to 18.degree., 13.degree. to 17.degree., 14.degree. to 16.degree.,
or any value therebetween (e.g., 15.degree.). The bottom or lower
base width (b) of the kerfed segments 32 (e.g., spacing between
kerfs 30 on centers) generally ranges from 0.60 inches to 1.60
inches, 0.65 inches to 1.60 inches, 0.70 inches to 1.55 inches,
0.75 inches to 1.50 inches, 0.60 inches to 1.00 inches, 0.75 inches
to 1.00 inches, 0.80 inches to 1.00 inches, 0.90 inches to 1.00
inches, 0.80 inches to 1.45 inches, 0.85 inches, to 1.40 inches, or
any value therebetween (e.g., 1 inch). The top or upper base width
(a) of the kerfed segments generally ranges from 0.45 inches to
0.85 inches, 0.50 inches to 0.80 inches, 0.50 inches to 0.75
inches, 0.50 inches to 0.70 inches, 0.50 inches to 0.60 inches, or
any value therebetween (e.g., 0.5 inches). As illustrated, the
kerfed segments 32 have trapezoidal-shaped cross sectional
configurations due to the v-shaped kerfs 30. Therefore, each of the
kerfed segments 32 have the bottom or lower base width (b), a top
or upper base width (a), and a thickness or height equivalent or
substantially equivalent to the thickness (Thk) of the insulation
board 20 (e.g., such that kerfs 30 do not penetrate through the
outside surface 24 or extend into the facing 28 as described
above).
[0044] The following equations allow specific dimensions of the
insulation board 20 illustrated in FIGS. 8A-8D and described herein
for a round duct to be determined or calculated accordingly.
L1=.pi.D (Equation 1)
L2=.pi.d, where d is the inner diameter or D-2Thk (Equation 2)
b=L1/n (Equation 3)
a=L2/n (Equation 4)
c=(b-a)/2, where c is 1/2 the width of the kerf opening at its
widest point (Equation 5)
.theta.=2(arctan(c/ThK)) (Equation 6)
As discussed above, when a thickness (Thk) and outer diameter (D)
or outer circumference (L1) of the insulation board are fixed, set,
or known depending on a diameter of the duct to be lined and
insulation thickness desired, the number (n) of kerfed segments 32
may be adjusted, selected, or determined such that the angle
.theta. between the two planes of the openings of kerfs 30 or the
bottom width (b) of the kerfed segments 32 are within the ranges
for improved fitting or lining of a round duct (e.g., a small
diameter duct). Angle .theta. may be converted from radians into
degrees as typically known.
[0045] According to an exemplary embodiment, for a 6 inch inner
diameter round duct (e.g., D=6 inches) and an insulation board 20
with an insulation thickness of 1 inch (e.g., Thk=1 inch), the
number of segments (n) may be selected such that the angle .theta.
between the two planes of the openings of kerfs 30 and the bottom
width (b) of the kerfed segments 32 are within the ranges to
provide improved fitting or lining of the 6 inch diameter round
duct. The insulation board 20 has an outer circumference (L1) or
may be cut to a width of 18.8496 inches based on equation 1. As an
example, the number of segments (n) may be selected to be 24. As
such, b is determined to be 0.7854 inches based on equation 3 and 9
is determined to be 14.92 in degrees (e.g., .theta. (180
degrees/.pi. radians)) based on equation 6. As the angle .theta.
between the two planes of the openings of kerfs 30 and the bottom
width (b) of the kerfed segments 32 are within the ranges discussed
above for round ducts, the kerfing is such that fit is improved
(e.g., less block-like appearance, better conformity, or reduced or
no sagging) or kerf gap reduced (e.g., reduced or no exposure of
insulation fibers to the gas stream surface of the duct).
[0046] With reference to FIGS. 9A-9D, similarly to round ducts as
described above with respect to FIGS. 8A-8D, at least one of: the
number (n) of kerfed segments 32, thickness (Thk), or outer
diameter (D) or outer circumference (L1) may be pre-determined,
adjusted, specified, or selected for an insulation board 20 such
that the angle .theta. between the two planes of the openings of
kerfs 30 or the bottom length (b) of the kerfed segments 32 are
within ranges to provide improved fitting or lining of a flat oval
duct. However, in contrast with round ducts, flat oval ducts have
half circular cross sections on opposing ends or sides of the duct
and flat portions extending between the half circular cross
sections. Therefore, the insulation board 20 has both kerfed and
unkerfed sections or segments (e.g., alternating kerfed and
unkerfed sections to line the two half circular and flat portions,
respectively). For example, the segments with kerfed segments 32
extend around or line the half circular cross sections (e.g., half
a round duct circumference with the same diameter) and the unkerfed
segments 33 extend or line the flat portions of the duct. Including
kerfed segments in the flat portions of the flat oval duct may
cause undesired sagging into the gas stream surface of the duct. A
height (H) of the flat oval ducts to be lined is substantially
equal to the diameter (D) of the half circular cross sections.
Systems and methods for forming kerfed and unkerfed segments for
flat oval ducts are described in more detail below with respect to
FIGS. 10-12B. Further, as the kerfed segments 32 only extend around
half circular cross sections, the outer circumference (L1) is equal
to .pi.D/2 as shown below for flat oval ducts. Specific dimensions
of the insulation board 20 illustrated in FIGS. 9A-9D and described
herein for a flat oval duct may be determined or calculated based
on the equations below.
[0047] The following equations allow specific dimensions of the
insulation board 20 illustrated in FIGS. 9A-9D and described herein
for a flat oval duct to be determined or calculated
accordingly.
L1=.pi.D/2 (Equation 7)
L2=.pi.d/2, where d is the inner diameter or D-2Thk (Equation
8)
b=L1/n (Equation 9)
a=L2/n (Equation 10)
c=(b-a)/2, where c is % the width of the kerf opening at its widest
point (Equation 11)
.theta.=2(arctan(c/ThK)) (Equation 12)
[0048] According to an exemplary embodiment, for a 12 inch or about
12 inch inner diameter or height (H) flat oval duct (e.g.,
D=11.8125 inches) and an insulation board 20 with an insulation
thickness of 1 inch (e.g., Thk=1 inch), the number of segments (n)
may be selected such that the angle .theta. between the two planes
of the openings of kerfs 30 or the bottom width (b) of the kerfed
segments 32 are within the ranges described above for improved
fitting or lining of the 12 inch diameter flat oval duct. Each of
the kerfed segments 32 of insulation board 20 (e.g., to line
opposing half circular ends) have an outer circumference (L) or may
be cut to a width of 18.5550 inches based on equation 7. As an
example, the number of segments (n) may be selected to be 12. As
such, b is determined to be 1.5463 inches based on equation 9 and 6
is determined to be 14.92 in degrees (e.g., .theta. (180
degrees/.pi. radians)) based on equation 12. As the angle .theta.
between the two planes of the openings of kerfs 30 or the bottom
width (b) of the kerfed segments 32 are within the ranges discussed
above for flat oval ducts, the fit is improved (e.g., less
block-like appearance, better conformity, or reduced or no sagging)
or kerf gap reduced or substantially eliminated (e.g., reduced or
no exposure of insulation fibers to the gas stream surface of the
duct). The flat portions of the duct to be lined may be measured to
determine the widths of the unkerfed segments 33.
[0049] With reference to FIGS. 10-12B, the v-shaped kerfs 30 or
kerf segments 32 for the improved fit duct liner insulation
embodiments described herein may be formed with pre-determined or
specific dimensions by a plurality of appropriately spaced and
driven tapered end mill bits (FIG. 10) or sets of stacked steel,
ceramic or carbide saw blades of various diameters (FIGS. 11A-12B).
As discussed above, for improved fit or conformity within a round
or flat oval duct, the insulation board may be provided or
manufactured with particular kerfing characteristics or dimensions
(e.g., the angle .theta. between the two planes of the openings of
kerfs 30 ranges from 12.degree. to 18.degree., thickness Thk, or
other kerf or kerfed segment dimensions as described herein). As
illustrated in FIG. 10A-10B, a tapered router or end mill bit 60
may be sized to cut or remove a v-shaped kerf 30 from the
insulation boards as described herein with the depth (e.g., through
the thickness Thk of the insulation board) and angle .theta. (e.g.,
15.degree.) required for improved or better fit or conformity when
installed within a curvilinear duct. A height of the bit 60 may
correspond to the desired depth of the v-shaped kerf to be formed
or the thickness Thk of the insulation board. For example, a bit
with a height of 2 inches may cut or form a kerf having a depth of
2 inches or about 2 inches (e.g., without cutting into or through
the facer or second major surface). The bit 60 may be operably
coupled to a computer numerical control (CNC) milling machine 62
for cutting or removing rows of spaced apart kerfs as desired. In
other embodiments, a plurality of bits 60 may be attached or
operably coupled to the CNC milling machine to cut or remove rows
of spaced apart kerfs concurrently or simultaneously.
[0050] FIGS. 11A-11B illustrate an improved kerfing apparatus 100
configured in accordance with another embodiment of the present
invention. Related duct liner insulation kerfing or grooving
apparatuses are described in greater detail below and in U.S. Pat.
Nos. 5,855,154 and 3,875,835, both of which are incorporated herein
by reference for all purposes in their entireties. The kerfing
apparatus 100 may include one or more of sets of stacked circular
saw blades 102 (e.g., equal to number of kerfed segments (n)-1)
mounted on a rotatable shaft 106 (e.g., an axle or drive shaft) and
configured to cut or form v-shaped kerfs (e.g., kerfs 30) from
insulation boards as described herein with the dimensions (e.g.,
depth) or angles (e.g., .theta.) for improved fit. For example, if
24 kerfed segments 32 are desired, then 23 sets of blades 102 may
be provided such that the 24 kerfed segments may be kerfed
concurrently or simultaneously.
[0051] Each set of stacked circular saw blades 102 includes an odd
number of saw blades 104 with varying diameters (e.g., three or
more) such that v-shaped kerfs may be cut or approximated. For
example, as illustrated in FIG. 11A, the set of stacked circular
saw blades 102 includes 7 individual saw blades 104. A center or
central saw blade 104a has the largest diameter with blades (e.g.,
blades 104b, 104c, 104d) having progressively smaller diameters
(e.g., diameter of each subsequent blade 104 is stepped down)
stacked on or flanking each side of the center saw blade 104a in a
mirrored configuration. The diameter of each blade 104 within the
set 102 and the number of saw blades 104 may be sized to cut or
remove a v-shaped kerf with desired or appropriate depth (e.g.,
about 1 to 4 inches) depending on thickness Thk of the insulation
board such that the kerfs 30 do not do not extend into the facing
28 or penetrate through the second major surface 24 or angle
.theta. (e.g., 12-18 degrees) through the thickness of the
insulation board 20 as described in more detail below. Further, in
some embodiments, to provide a minimum cutting tolerance between
diameters of the shaft 106 and the blades 104, the smallest
diameter blade 104 may sized to be at least 0.5 to 1.0 inches, or
any value therebetween larger in diameter relative to the shaft 106
diameter. In some embodiments, the shaft may include spacer
sleeves. In such embodiments, the smallest diameter blade 104 may
sized to be at least 0.5 to 1.0 inches, or any value therebetween
larger in diameter relative to the shaft 106 diameter combined with
the thickness of the spacer sleeves.
[0052] The rotatable shaft 106 may be operably coupled to a single
power source 105 (e.g., a motor) for rotating or turning the shaft
during a kerfing process. The shaft 106 may have a non-round (e.g.,
hexagonal) cross sectional configuration. In other embodiments, the
shaft may have a round or other suitable cross sectional
configuration (e.g., square or rectangular). The blades 104 or sets
of blades 102 may be slid on or off (e.g., installed or removed) as
necessary for reconfiguration, repair, or replacement.
[0053] Further, the apparatus 100 may include one or more spacers
or spacer sleeves 108 disposed or positioned between or
intermediate sets of blades 102. A width of the sleeves 108 may be
equal to or substantially equal to (e.g., set or selected) to the
top or upper base length (a) of the kerfed segments 32 between
kerfs 30. Therefore, the width of the sleeves may be varied to vary
the width (a) of the kerfed segments 32 of an insulation board 20.
Mounting openings in the rotary saw blades 104 or the spacer
sleeves 108 may be complementary in cross section to the cross
section of the drive shaft 106. In some embodiments, mounting
openings of the spacer sleeves 108 are non-complementary (e.g.,
round relative to hexagonal). Accordingly, the rotary saw blades
104 or the spacer sleeves 108 may rotate with the drive shaft and
can be readily removed from or placed on the drive shaft 106. A
shaft 106 with a non-round or hexagonal cross sectional
configuration may allow axial positions of the blades 104 or spacer
sleeves 108 to be fixed relative to the shaft without additional
support arms, set screws, keying, or the like. A shaft with a round
configuration may be keyed 109 (FIGS. 12A-12B) and mounting
openings of the blades 104 or spacer sleeves provided with a
complementary key portion such that axial positions of the blades
104 or spacer sleeves 108 may be fixed accordingly.
[0054] As described above, to line flat oval ducts, the insulation
board 20 may have both kerfed and unkerfed sections or segments
(e.g., alternating kerfed and unkerfed sections to line the two
half circular and flat portions, respectively). In such
embodiments, the apparatus may include one or more spacers or
spacer sleeves 108 having a width equal to or substantially equal
to a width of the flat portions. In some embodiments, the apparatus
100 includes two spacers or spacer sleeves alternating with sets of
blades 102 to form unkerfed segments corresponding to the widths of
the flat portions and kerfed segments corresponding to widths or
circumferences required for the circular portions, respectively.
For the kerfed segments, the apparatus may include smaller spacer
sleeves to space apart the sets of blades 102 within the kerfed
segments. While not illustrated in FIGS. 11A-12B, each of the
blades 104 may include teeth for cutting the kerfs 30. Further, the
apparatus 100 may include feed rolls for passing insulation boards
through the apparatus for kerfing. In yet further embodiments,
instead of blades 104 or end mill bits 60, the kerfs 30 may be cut
with a laser.
[0055] With reference to FIGS. 13A-13B, an improved system and
method of forming duct liner insulation for flat oval ducts (e.g.,
FIGS. 4-5) with separate or multiple unkerfed and kerfed segments
as described herein is provided. While, unitary or monolithically
formed insulation boards 20 may be provided with kerfed and
unkerfed segments as described above, in certain embodiments, the
kerfed and unkerfed segments 210 and 212 may be formed separately
(FIG. 13A) and later joined or otherwise coupled together (FIG.
13B). Kerfed segments may be formed as described herein for
improved fit of a round duct. For example, for a flat oval duct
with circular ends having a diameter (D) or height (H), a kerfed
insulation board formed according to embodiments as described
herein to improve fit within a round duct with a diameter (D) equal
to the diameter (D) or height (H) of the flat oval duct may be
used. The kerfed insulation board for the round duct may be cut in
half for example, with each half (e.g., kerfed segment 210a and
kerfed segment 210b) used to line the opposing circular ends of the
flat oval duct. Unkerfed segments 212a and 212b may then be sized
for the flat portions of the flat oval duct. The separately formed
kerfed and unkerfed segments may be joined (e.g., butt joints glued
or taped along a length of the segments) and installed within the
flat oval duct. While four separate pieces are illustrated (e.g., 2
kerfed and 2 unkerfed segments), in other embodiments, other
combinations may be formed and joined as well. For example, two
separate pieces, three separate pieces, or more.
[0056] While referring specifically to lining curvilinear ducts
including round and flat oval ducts in several embodiments, the
duct liner insulation 10 may be installed or line ducts with other
cross sectional configurations including square, rectangular, or
triangular. Additionally, in some embodiments, the duct liner
insulation 10 may be used to insulate or line duct transitions and
fittings as well. Further, the duct liner insulation 10 may in
addition, or instead, may line or insulate an exterior or outer
surface of an insulated pipe or duct (e.g., as an external wrap or
liner).
[0057] While several embodiments and arrangements of various
components are described herein, it should be understood that the
various components and/or combination of components described in
the various embodiments may be modified, rearranged, changed,
adjusted, and the like. For example, the arrangement of components
in any of the described embodiments may be adjusted or rearranged
and/or the various described components may be employed in any of
the embodiments in which they are not currently described or
employed. As such, it should be realized that the various
embodiments are not limited to the specific arrangement and/or
component structures described herein.
[0058] In addition, it is to be understood that any workable
combination of the features and elements disclosed herein is also
considered to be disclosed. Additionally, any time a feature is not
discussed with regard in an embodiment in this disclosure, a person
of skill in the art is hereby put on notice that some embodiments
of the invention may implicitly and specifically exclude such
features, thereby providing support for negative claim
limitations.
[0059] Having described several embodiments, it will be recognized
by those of skill in the art that various modifications,
alternative constructions, and equivalents may be used without
departing from the spirit of the invention. Additionally, a number
of well-known processes and elements have not been described in
order to avoid unnecessarily obscuring the present invention.
Accordingly, the above description should not be taken as limiting
the scope of the invention.
[0060] Where a range of values is provided, it is understood that
each intervening value, to the tenth of the unit of the lower limit
unless the context clearly dictates otherwise, between the upper
and lower limits of that range is also specifically disclosed. Each
smaller range between any stated value or intervening value in a
stated range and any other stated or intervening value in that
stated range is encompassed. The upper and lower limits of these
smaller ranges may independently be included or excluded in the
range, and each range where either, neither or both limits are
included in the smaller ranges is also encompassed within the
invention, subject to any specifically excluded limit in the stated
range. Where the stated range includes one or both of the limits,
ranges excluding either or both of those included limits are also
included.
[0061] As used herein and in the appended claims, the singular
forms "a", "an", and "the" include plural referents unless the
context clearly dictates otherwise. Thus, for example, reference to
"a process" includes a plurality of such processes and reference to
"the device" includes reference to one or more devices and
equivalents thereof known to those skilled in the art, and so
forth. The term "or" in reference to a list of two or more items,
covers all of the following interpretations of the word: any of the
items in the list, all of the items in the list, and any
combination of items in the list.
[0062] Also, the words "comprise," "comprising," "include,"
"including," and "includes" when used in this specification and in
the following claims are intended to specify the presence of stated
features, integers, components, or steps, but they do not preclude
the presence or addition of one or more other features, integers,
components, steps, acts, or groups.
* * * * *