U.S. patent number 3,885,593 [Application Number 05/316,023] was granted by the patent office on 1975-05-27 for stretchable reinforced wrapper for insulated flexible duct.
This patent grant is currently assigned to Automation Industries, Incorporated. Invention is credited to Marvin A. Koerber, Charles G. Richitelli.
United States Patent |
3,885,593 |
Koerber , et al. |
May 27, 1975 |
Stretchable reinforced wrapper for insulated flexible duct
Abstract
A stretchable but reinforced wrapper or moisture and air barrier
is used in the fabrication of insulated flexible duct for air
conditioning, heating, and ventilating systems. The wrapper is a
laminate of one or more films having an inherent stretch or
elongation characteristic in both axial and bi-axial directions,
and a reinforcing material of fabric or fiber for reinforcing the
film layer or layers while still allowing bi-axial stretch or
elongation of the wrapper and duct.
Inventors: |
Koerber; Marvin A. (Abbeville,
SC), Richitelli; Charles G. (Greenwood, SC) |
Assignee: |
Automation Industries,
Incorporated (Los Angeles, CA)
|
Family
ID: |
23227130 |
Appl.
No.: |
05/316,023 |
Filed: |
December 18, 1972 |
Current U.S.
Class: |
138/128; 138/107;
138/149; 138/172; 138/131 |
Current CPC
Class: |
F16L
59/153 (20130101); F24F 13/0263 (20130101); F24F
13/0218 (20130101); B32B 1/08 (20130101); B32B
27/06 (20130101); F16L 59/021 (20130101); B32B
27/12 (20130101); B32B 2307/7265 (20130101); B32B
2305/08 (20130101); B32B 2307/304 (20130101); B32B
2597/00 (20130101); B32B 2307/7246 (20130101); B32B
2307/52 (20130101) |
Current International
Class: |
F16L
59/00 (20060101); F16L 59/153 (20060101); F16L
59/02 (20060101); F16l 011/12 () |
Field of
Search: |
;138/118,119,122,133,138,107,129,130,131,137,139,128,172 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Myracle; Jerry W.
Attorney, Agent or Firm: Sadler; Dan R.
Claims
Having thus described embodiments of the invention, what we claim
is:
1. An insulated flexible duct for being interconnected with a rigid
cylindrical fitting in an air-conditioning, heating, and
ventilation systems, said duct including the combination of:
a hollow central reinforcing core, said core including an
elongated, helical, semi-rigid wire spring, forming a cylindrical
passage for air to flow-therethrough;
a layer of insulating material disposed about said cylindrical core
to limit the radial flow of heat through said duct;
a thin film of plastic wrapped about the layer of insulating
material to form a vapor barrier on the exterior of said duct, said
film being impervious to the flow of moisture and air and
stretchable in random directions;
a first set of reinforcing threads in said vapor barrier extending
helically around said duct in a first direction; and
a second set of reinforcing threads in said vapor barrier extending
helically around said duct in a second direction, said first and
second directions being at substantially right angles to each other
whereby said vapor barrier may be circumferentially stretched.
2. An insulated flexible duct for use in air-conditioning, heating,
and ventilating systems, said duct including the combination
of:
a central flexible core structure for reinforcing the duct, said
core structure having a resilient spring forming a cylindrical
passage for the flow of air therethrough;
a cylindrical layer of insulation surrounding said core, said
insulation being effective to insulate said passage against thermal
losses;
an outer vapor barrier enclosing and covering said cylindrical
layer of insulation, said vapor barrier including at least one film
impervious to moisture and air, and,
reinforcing means in said film, said reinforcing means including a
plurality of inelastic threads said threads being constructed and
arranged in said film to prevent ripping and tearing of the vapor
barrier but not effect the axial and circumferential stretching of
the duct.
3. An insulated flexible duct, comprising:
an elongated, helical, semi-rigid, wire core;
insulating material disposed about said wire core;
a vapor barrier disposed about said insulating material;
reinforcement means in said vapor barrier, said reinforcing means
being constructed and arranged to protect said vapor barrier
against rips and tears while still allowing circumferential
stretching of said vapor barrier,
said vapor barrier including at least one moisture and air
impervious film with inherent elongation in both axial and
circumferential directions, and
said reinforcement means includes reinforcement material arranged
to increase the durability, strength and puncture and
tear-resistance of said vapor barrier without the loss of axial
elongation thereof.
4. The duct according to claim 3, wherein said reinforcement
material is disposed as a plurality of spaced parallel reinforcing
yarns in said axial direction only.
5. The duct according to claim 4, wherein said reinforcing yarns
are monofiliment strands.
6. The duct according to claim 4, wherein said reinforcing yarns
are twisted yarns.
7. The duct according to claim 3, wherein said reinforcement
material is disposed as a tri-directional array having a set of
spaced parallel reinforcing yarns lying in said axial direction,
and two intersecting spaced parallel reinforcing yarn sets each
disposed at an angle of less than 90.degree. to said axial
direction.
8. The duct according to claim 7, wherein said angle is
45.degree..
9. The duct according to claim 7, wherein said reinforcing yarns
are monofiliment strands.
10. The duct according to claim 7, wherein said reinforcing yarns
are twisted yarns.
11. The duct according to claim 3, wherein said reinforcement
material is disposed as a bi-directional array having two sets of
spaced parallel reinforcing yarns, said sets intersecting each
other and being at an angle less than 90.degree. to said axial
direction.
12. The duct according to claim 11, wherein said reinforcing yarns
are monofiliment strands.
13. The duct according to claim 11, wherein said reinforcing yarns
are twisted yarns.
14. The duct according to claim 3, wherein said reinforcing
material is essentially a bi-directional array having an axial set
of spaced parallel reinforcing yarns and a bi-axial set of spaced
and essentially parallel reinforcing yarns, said axial set
preventing axial elongation of said vapor barrier while said
bi-axial set being configured to allow biaxial elongation
thereof.
15. The duct according to claim 14, wherein said biaxial set of
yarns is in a crimped pattern.
16. The duct according to claim 14, wherein said biaxial set of
yarns is in a taslan pattern.
17. The duct according to claim 14, wherein said biaxial set of
yarns is in a sinusoidal pattern.
18. The duct according to claim 14, wherein said biaxial set of
yarns is in a high-twist pattern having greater than a six turns
per inch in an S direction.
19. The duct according to claim 14, wherein said biaxial set of
yarns is in a high-twist pattern having greater than a six turns
per inch in an Z direction.
20. The duct according to claim 14, wherein said biaxial set of
yarns is a spaced plurality of groupings of yarn twisted in only
one direction in an unbalanced construction.
21. The duct according to claim 14, wherein said biaxial set of
yarns is a plurality of spaced yarns having inherent elongation of
approximately 15%.
22. The duct according to claim 14, wherein said biaxial set of
yarns is woven into said axial set of yarns.
23. The duct according to claim 14, wherein said biaxial set of
yarns is in a non-woven relation with said axial set of yarns.
24. The duct according to claim 3, wherein said reinforcement
material has an inherent stretch similar to that of said film and
is in a spunbonded non-woven configuration.
25. Insulated flexible duct for use in air-conditioning, heating,
and ventilating systems and the like, the duct including the
combination of:
insulated flexible ducting;
an outer wrapper surrounding said ducting, said wrapper including
at least one moisture and air impervious film layer having inherent
elongation in both axial and circumferential directions,
reinforcement means including reinforcement material laminated to
said film layer for reinforcing said film layer while still
allowing axial elongation of said wrapper.
26. Insulated flexible ducts for use in air-conditioning, heating,
and ventilating systems, and the like, the duct including the
combination of:
a central flexible reinforcing core;
an inner layer of insulation surrounding said core;
an outer protective vapor barrier enclosing said layer of
insulation, said vapor barrier having at least one moisture and air
impervious film with inherent elongation in both axial and
circumferential directions, and
a plurality of fibers in said film for reinforcing said film, said
fibers being oriented relative to the axis of said duct while still
allowing axial and circumferential elongation of said vapor
barrier.
27. Insulated flexible ducts for use in air-conditioning, heating,
and ventilation systems, and the like, the duct including the
combination of:
an elongated, helical, semi-rigid wire core;
insulative material disposed about said helical wire core;
a vapor barrier layer disposed about said insulative material, said
barrier layer having at least one moisture and air impervious film
with inherent elongation in both axial and circumferential
directions, and
reinforcing threads, said threads being inelastic and laminated to
said film in a direction oblique to the axis of the duct for
reinforcing said film while still allowing axial and
circumferential elongation of said vapor barrier.
Description
BACKGROUND
In a building having a centralized air-conditioning system, the air
is cooled, filtered, etc., by centrally located air-conditioning
machinery. The conditioned air is then distributed throughout the
building by a suitable distribution system. Historically, such
distribution systems have utilized rigid sheet metal ducts. Because
of the high thermal conductivity of metal, if the exterior of the
duct is exposed to the surrounding warm air, there is a very
substantial warming of the otherwise cool air and a considerable
amount of moisture condenses on the exterior of the duct.
Accordingly, a suitable installing material has normally been
applied to the exterior of the sheet metal duct. This, of
necessity, normally occurs subsequent to the installation.
Because of the rigid nature of sheet metal ducts, they must be
precisely cut to the correct dimensions and precisely mounted and
installed. Since the installation in any given building is an
essentially customized project, it does not lend itself to any
significant degree of standardization. Moreover, the installation
requires a considerable amount of time by a very skilled and highly
paid operator, such as a sheet metal worker. As a result, such
ducts are very expensive to assemble and install.
More recently, it has been proposed to overcome the foregoing
difficulties by utilizing essentially standardized flexible ducts.
Ducts of this nature normally have an inner supporting structure or
core. By way of example, the core may include a flexible spring or
similar member. An insulating material such as a blanket or mat of
fiberglass surrounds the core and is supported thereby. An outer
wrapper or a vapor barrier surrounds this insulating blanket.
When a flexible duct of the foregoing variety is installed, it is
easily cut to the desired length and quickly installed. Because of
the flexible nature of the duct, it is not absolutely essential
that the duct be precisely cut to the exact length nor that the
mountings, supports, fittings, etc., be precisely positioned.
Instead, a considerable amount of latitude is possible in its
dimensions and positions. Moreover, the easy cutting and handling
of the flexible ducts and the loose tolerances in their
installation allow the use of workmen having very little
specialized skill and a minimum amount of tools and equipment.
These ducts are now capable of being manufactured by a fully
automatic and continuous process in virtually unlimited lengths
with a minimum amount of human labor. A machine and method
particularly suitable for manufacturing this type of insulated
flexible duct is described in U.S. Pat. No. 3,627,615, entitled
"Machine for Manufacturing Ducting" filed in the name of Wesley L.
Guiles and Marcus A. Hall and assigned of record to Automation
Industries, Inc.
The machine disclosed in the above mentioned patent has solved or
eliminated many of the problems associated with the production of
insulated, flexible ducting whereby the use of such ducting is
becoming more wide spread. However, there still remain certain
problems relating to the use and/or installation of such ducting.
When the flexible duct is installed, at least one end of the duct
is attached to a rigid sheet metal duct such as one from the plenum
chamber and/or on the outlet fitting such as a distribution box.
Normally the outer vapor barrier of the flexible duct has been a
non reinforced sheet of film of a plastic such as Mylar, PVC or
CPE. Such a vapor barrier possesses a certain amount of stretch
whereby it can be circumferentially expanded to fit over the sheet
metal duct or fitting. This greatly facilitates installation and/or
servicing. However, if the vapor barrier is not reinforced, it
tends to rip and tear readily. If the barrier is punctured, the
resultant hole will grow into a tear which eventually results in a
useless duct.
In order to overcome the foregoing difficulties, some of the
flexible duct manufacturers have attempted to find a vapor barrier
which has greater durability, strength, puncture-resistance, and
tear-resistance. This has normally been accomplished by using a
vapor barrier which has one or more plastic films or sheets
laminated or bonded onto some form of fabric. The fabric has
included a set of threads which extend longitudinally of the
plastic sheet and a second set of threads which extend transversely
of the plastic sheet. When this sheet is wrapped around the duct,
the threads in the resultant vapor barrier extend circumferentially
and axially of the duct. These threads have been effective to
reinforce the vapor barrier and thereby increase the durability,
puncture and tear-resistance of the barrier. However, they have
also limited the amount of circumferential and axial stretch of the
duct. As a consequence, it has been difficult to stretch the duct
over and onto a sheet metal duct. It has also made it difficult to
stretch the duct axially to extend from one point to another when
the duct has been cut a little too short.
SUMMARY
The present invention provides means for overcoming the foregoing
limitations and difficulties. More particularly, the present
invention provides a stretchable reinforced protective wrapper or
vapor barrier for insulated flexible ducts used in
air-conditioning, heating, and ventilating systems and the
like.
In an embodiment of the invention disclosed herein, a flexible
insulated duct is provided which has a stretchable reinforced
protective vapor barrier. The barrier includes at least one
moisture and air impervious film barrier having in hand an
elongation or stretch in both the axial and circumferential
directions. The barrier also includes reinforcement means having
reinforcing material laminated to the film layer for reinforcing
the film layer while still allowing axially and circumferential
elongation of the vapor barrier.
The invention and a limited number of specific embodiments thereof
are described hereinafter by way of example and with reference to
the accompanying drawings in which like reference characters refer
to like elements in the several views.
DRAWINGS
FIG. 1 is a side view of a type installation of insulated flexible
duct having a stretchable reinforced or vapor barrier constructed
in accordance with the present invention;
FIG. 2 is a fragmentary view of a portion of the insulated flexible
duct of FIG. 1 with an end stretched over a standard rigid end
fitting;
FIG. 3 is a view illustrating a section of the vapor barrier on the
duct, said vapor barrier reinforced in accordance with an
embodiment of the present invention;
FIG. 4 is a view similar to FIG. 3 but of a section of vapor
barrier having a reinforcement in accordance with another
embodiment of the present invention;
FIG. 5 is a view of a section of a vapor barrier having another
form of reinforcement;
FIG. 6 is a sequence of view of parts of several vapor barriers
having several different types of reinforcement; and
FIG. 7 is a view of a section of a vapor barrier using a still
further form of reinforcement.
DESCRIPTION
Referring to the drawings in more detail and particularly to FIG.
1, there is shown a length of insulated flexible duct 11
constructed with a stretchable reinforced outer wrapper or vapor
barrier in accordance with the present invention. One end of the
duct is connected to a runout fitting in the side of a conventional
distribution duct or plenum chamber 13 of a central
air-conditioning system. A portion of the air in the plenum chamber
13 flows into the duct to be carried thereby.
The outlet end 14 of the duct 11 is connected to a standard end
fitting 15 of a conventional diffuser outlet 16 in a false ceiling
17. In a typical configuration, the diffuser directs the air
through the ceiling 17 into the room below. The plenum chamber 13
may be suspended from a runner 19 in the overhead structure 20.
The air-conditioning duct 11 is shown supported at several points
along its length by wire hangers 21 threaded through grommets 23.
The grommets 23 are mounted in an "upstanding" longitudinal seam 25
forming an integral part of the outer wrapper or vapor barrier 27.
The seam 25 is formed by folding the mating edges of the vapor
barrier 27 and sealing them together. The grommets 23 are then
punched through the seam and clinched therein. The wire hangers 21
are attached to and suspended from the angle iron runner 19
attached to a convenient building structure such as a rafter or
beam 20, etc., forming a part of the ceiling structure.
An embodiment of the present invention is illustrated in more
detail in FIGS. 2 and 3. Here, a flexible and easily bent duct 11
is shown to have a central flexible reinforcing core 41. The core
includes helical spring 43 of a semi-rigid steel wire. The spring
43 is an essentially self-supporting structure having sufficient
strength (particularly in its radial direction) to insure the duct
11 being maintained in its normally cylindrical shape. However, the
shape of the duct is optional, and the spring 43 is normally of a
rigidity to allow the finished product to be bent and distorted as
may be required for installation.
Although a bare or synthetic (vinyl) coated wire spring may be used
along for the core 41, in the present instance a so-called "scrim
cloth" 45 is wrapped around the wire spring 43 and attached thereto
by any suitable bonding means. A cloth of this type is a
light-weight, coarse, loosely-woven material. For example, it may
have on the order of 10 to 20 threads or strands per inch with a
corresponding number of openings per inch.
This "scrim cloth" 45 will, to some degree, limit the extent to
which the spring 46 can be axially expanded but will not materially
affect the bending or axial compression of the core 41. Another
advantage of the scrim cloth is that the helical spring cannot
"escape" or unravel when the duct is cut to lengths by an
installer.
The duct 11 also includes one or more layers 47 of thermal
insulation. The insulation may be of any desired material. Normally
the insulating layer 47 is formed of a flexible material, such as a
blanket of fiberglass. This blanket is normally of sufficient
thickness to insure a minimum amount of heat being transferred
between the outside and inside of the duct 11 particularly when
cold air is flowing there through. By way of example, the
insulation may be on the order of about 1/2 inch to about 2 inches
or more in thickness.
As noted previously, the duct 11, as seen in FIG. 1, is covered by
an outer wrapper or vapor barrier 27. This is vapor barrier 27
intended to enclose or cover the duct 11 and protect it from damage
during normal handling and use. Accordingly, the outer cover or
vapor barrier 27 should be a tough material which is durable,
strong, not easily torn, punctured, etc. The vapor barrier 27 is
also intended to prevent the air inside of the duct 11 escaping
outwardly through the insulating material and to keep moisture,
etc., which may condense on the exterior of the duct, from being
absorbed in the insulating material and/or entering radially into
the interior of the duct.
As clearly seen in FIG. 2, the end portion 14 of the duct 11 is
stretched circumferentially to fit over the end of the standard
fitting such as a sheet metal tube 15 on the diffuser 16 or the
run-out fitting in the side of the plenum chamber 13. This
illustrates still another and very desirable characteristic of the
present invention, its circumferential flexibility without loss of
outdoor weathering, permeability, strength, and puncture and
tear-resistance qualities.
The vapor barrier 27 shown in FIG. 2 and more clearly in FIG. 3,
encloses and protects all of the various parts of the duct 11
including particularly the insulating material such as fiberglass.
The vapor barrier 27 should also be effective to prevent the loss
of air by its flowing radially out through the insulating material
and to prevent any moisture which condenses on the outside of the
duct 11 working its way into the insulation.
It has been found there are a large variety of plastic sheets or
films which are readily commercially available that are well suited
for this purpose. For example, thin films of materials such as PVC,
Mylar, (Mylar is a registered trademark of DuPont), and CPE, etc.,
are well suited for this purpose.
These films have inherent stretch or elongation in all random
directions. Films of this nature are impervious to air and moisture
and can be readily stretched in any random direction. However, they
can be easily punctured by any sharp object. They can also be
easily ripped or torn, particularly once there is an initial
opening, such as a puncture. As a consequence, any hole will
rapidly grow to a very large size.
In order to avoid this difficulty, the vapor barrier 27 is
reinforced. However, the reinforcement does not impair the ability
of the vapor barrier 27 to stretch so as to accommodate the
installation of the duct. Normally the reinforcement includes
members such as one or more sets of threads. The film 55 and the
reinforcing are bonded or laminated together by any suitable
process.
The reinforcing material 57 is arranged in such a manner that it
does not restrict the inherent stretching or elongation qualities
of the film 55, at least these qualities are not effected in a way
which will materially or adversely alter the circumferential and
axial stretching of the finished duct 11 or the parts thereof such
as required for installing the duct 11.
In the embodiment of the invention illustrated in FIGS. 2 and 3 the
reinforcing material 57 includes two separate sets of threads. All
of the threads 65A in one set are parallel to each other while all
of the threads 65B in the other set are parallel to themselves.
Moreover, all of the threads 65A in the first set are orthogonal to
all of the threads 65B in the other set. However, all of the
threads 65A and 65B in both of the sets are oblique to the edges of
the original strip of plastic. Normally the threads 65A and 65B are
set at approximately 45.degree. to the edges of the strip of
plastic substantially as shown in FIG. 3. In other words, all of
the threads are at approximately 45.degree. to both the length and
width of the strip. Conversely there are no threads which extend
either longitudinally or transversely of the strip.
The threads 65A and 65B may be bonded and/or laminated onto the
plastic film by any suitable means. The threads or sets of threads
may be individually applied to the film or they may be in the form
of a fabric. The threads 65A and 65B usually are fairly strong and
not capable of being stretched to any great extent. The number and
spacing of the threads are not believed to be particularly
critical. By way of example they may be spaced in a range of about
ten per inch to about one per inch.
During the final phases of constructing the duct 11 (i.e., after
the layer of insulation 47 has been placed around the flexible core
41) the strip of reinforced plastic is positioned to extend the
length of the duct 11. The strip is then wrapped around the outside
of the insulation and the two edges are brought together. The edges
are then folded over each other and bonded together to form the
stand-up seam. Following this a series of grommets may be punched
into the seam 25.
It may be seen that since the threads 65A and 65B extend diagonally
across the plastic strip, when the strip is cylindrically wrapped
around the layer of insulation to form the vapor barrier 27 the
threads 65A and 65B form two sets of helical reinforcements. In
other words, the threads 65A and 65B extend helically or spirally
around the duct 11 in two opposite directions.
There are no threads which extend either axially of the duct or
circumferentially around the duct. As a result, the vapor barrier
27 can be stretched in both the axial and circumferential
directions.
In order to install the duct 11 in an air conditioning system
(i.e., to extend from the plenum chamber 13 to the diffuser outlet
16) the duct 11 is cut to a length corresponding to the distance
between chamber 13 and the outlet 16. This should be cut as
accurately as reasonably practical. If the duct 11 is cut too long
it will have trends or undulatives which reduce the air flow. Next
the duct 11 is suspended from the overhead structure by means of
the suspension hooks or hangers 21 extending from the runner 19 and
the grommets 23.
After the duct 11 is in position and its weight is fully supported
by the hangers 21, the opposite ends of the duct 11 are attached to
the run out fitting in the side of the plenum chamber 13 and to the
fitting 15 on the diffuser outlet 16. In order to attach the end of
the duct 11 to the fitting 15, the end 14 of the duct 11 is
circumferentially stretched so as to expand it enough to fit over
and encompass the fitting 15.
In order to attach the end of the duct to the fitting the end
portion of the cover or vapor barrier 27 is normally folded back on
itself for a distance of several inches. This forms a cuff in the
end of the vapor barrier 27 and exposes the end portion of
insulating layer and the core structure. It can be appreciated that
in order to fold the vapor barrier 27 back on itself, it is
essential that it have a considerable amount of circumferential
stretch. Without the stretch it is extremely difficult to fold the
barrier 27 back upon itself without tearing it.
Next the core structure is worked onto fitting 15. In order to do
this it may be necessary or at least desirable to fold or work the
insulation back so as to expose the core structure. After the end
of the core structure is properly seated upon the fitting, the
insulating material is worked back around the core structure. It is
also worked around the exposed portion of the fitting 15. This is
effective to provide insulation for the fitting.
The cuff originally formed in the vapor barrier 27 is now worked
forward and back over the insulating material. This is normally
accomplished by grasping the end of the barrier 27 and jerking it
forwardly. It can be appreciated that this necessitates a
stretching of the material in the vapor barrier 27. If there is no
stretch, it is highly probable the barrier 27 will be ripped.
Once the vapor barrier 27 is unfolded it may be pulled axially to
extend over and even slightly beyond the insulating material. This
will permit the vapor barrier 27 to be disposed on the fitting. The
vapor barrier 27 can be stretched axially to a limited extent.
Accordingly an adequate amount of the barrier 27 can normally be
worked onto the fitting to facilitate covering the fitting 15
and/or securing the duct 11 thereto.
Under some circumstances the fitting 15 may belong with a
substantial area exposed. In this event it is usually desirable to
insulate the fitting 15 and/or to provide a vapor barrier. To
accomplish the end of the vapor barrier 27 may be folded back on
itself for a distance in excess of the length of the fitting 15.
The exposed end of the duct (i.e., the insulating layer and core
structure) is then cut-off. When the vapor barrier 27 is again
pulled forward, it will extend beyond the end of the duct.
Accordingly, it can be used to cover up at least a portion of the
duct.
Since the reinforcing threads are all disposed in helical or spiral
arrays they will not materially interfere with this stretching of
the vapor barrier 27. As a consequence, the vapor barrier 27 can be
stretched circumferentially essentially according to the stretching
characteristics of the plastic film prior to its being reinforced
by the threads 65A and 65B.
It should also be noted that there are no threads extending in an
axial direction of the duct 11. As a consequence the duct 11 and
its reinforced vapor barrier 27 can be stretched axially. This
advantage is particularly important in these instances where the
duct is cut somewhat too short to freely reach between the
fittings. Under these circumstances, the duct 11 can be stretched
(i.e., within the limits of the core structure 41 and the layer of
insulating material 47) to reach to the fitting 15.
After the terminal end 14 of the duct 11 is stretched over and
around the fitting 15, it may be secured thereto by suitable
fastening means such as a clamp, tape, etc.
It may be observed that the reinforcing threads do not materially
or adversely effect the stretching of the vapor barrier 27 and/or
the duct 11 in either the circumferential and/or axial directions.
However, the reinforcing threads 65A and 65B are effective to
prevent or at least severly limit any ripping, tearing, puncturing
of the vapor barrier.
Under some circumstances the installer may rip or tear the vapor
barrier 27 adjacent the end 14 while trying to stretch it over the
fitting 15. Also, he may puncture the vapor barrier 27 by snagging
it on a sharp object while handling the duct. It is also possible
to snag and rip the barrier 27 after the duct 11 has been
installed, while installing other equipment next to the duct
11.
However, in the event, the vapor barrier 27 should happen to be
ripped, torn, punctured, etc., the resultant opening will not
propogate beyond the first reinforcing thread or two. Thus, even if
the reinforcing threads are relatively widely separated (for
example an inch or so) the puncture, rip, or tear, etc., will
normally not extend beyond a size of about one or two inches. An
opening of even this limited size is not a desirable feature.
However, the losses resulting therefrom are relatively nominal and
not large enough to totally destroy the effectiveness of the duct.
Moreover, since the opening will be retained within relatively
narrow dimensions, it can be readily repaired with a patch.
The foregoing embodiment is reinforced so as to prevent it ripping,
tearing etc., without materially restricting circumferential and/or
longitudinal stretching of the duct 11. Under some circumstances,
it may be desirable to prevent or at least limit the axial
stretching of the duct. It has been found that a limited amount of
axial stretching can be accommodated by the ducting. However, if
the duct 11 is stretched beyond the elastic limits of any of the
elements in the duct (i.e. the core structure and/or of the layer
of insulation) there may be a structural failure of one or more of
these elements.
Therefore, in order to control the axial stretch, the embodiment of
FIG. 4 may be employed. In this embodiment a tri-directional
reinforcement 57B is bonded or laminated onto the film 55. This is
effective to limit the elongation or stretch of the vapor barrier
27 in the axial or warp direction. However since there are no
transverse reinforcing threads it still allows an elongation or
stretch in the fill direction.
This type of reinforcement utilizes three separate sets of threads.
The threads in each set may be parallel monifiliment or twisted
yarns 71A, B and C placed in three different directions. One set
71A of axial or warp threads is placed to limit longitudinal
stretch or elongation of the laminate. The other two sets 71B and
71C of threads are disposed oblique to the axial or warp yarn set
71A. By way of example an angle of 45.degree. may be used.
The threads in the axial set 71A may be totally inelastic whereby
the vapor barrier 27 cannot be stretched. However, these threads
may also have a small amount of stretch whereby the barrier 27 may
stretch slightly, i.e., within the stretch limits of the core
structure and the insulating layer.
As a further alternative, the embodiment of FIG. 5 may be used.
This embodiment of the invention controls or essentially eliminates
axial stretch or elongation of the vapor barrier 27 and the duct
11. The film 55 is laminated to a reinforcement 57C. The
reinforcement 57C includes a plurality of parallel monifiliment or
twisted yarns 73 disposed in the axial direction only. This pattern
or array of reinforcements limits the stretch of the duct 11 in its
longitudinal direction. However, it still allows stretch or
elongation of the vapor barrier 27 (due to inherent film stretch)
in the circumferential direction.
As a further alternative, the embodiments of FIG. 6 may be used. In
this embodiment a fabric having transverse and longitudinal threads
is laminated to the plastic sheet or film. There are five versions
(6A to 6E) of this embodiment shown. Each of the versions includes
a laminate using special square-woven or special square non-woven
fabric. The reinforcements in the fabric limit elongation in the
axial (Warp) direction and allows elongation or stretch in the
circumferential (fill) direction.
In each version, an axially yarn pattern or set 75 of parallel
yarns is utilized. Along with this axially oriented pattern, as
seen in FIG. 6A, is a crimped or taslan type yarn set 77 disposed
in the fill direction. FIG. 6B shows a sinusoidal type placement of
a fill yarn set 79. A yarn set 81 of high-twist yarns (greater than
six turns per inch) in an S or Z direction is illustrated in FIG.
6C. In FIG. 6D, a yarn set 83 is shown wherein the plurality of
yarns are twisted in only one direction, S or Z for example, to
yield an unbalanced construction of high-elongation in the fill
direction. Finally, FIG. 6E shows a version wherein a conventional
yarn set 85 having an inherent elongated characteristic of
approximately 15% is woven or disposed in the fill direction.
In yet a further embodiment of the invention, the wrapper 27 takes
the form of a film or films 87, similar to film 55, laminated to a
spunbonded non-woven reinforcement 89 of such material as
polyester, polypropylene or polyolefin, which has inherent stretch
qualities similar to that of the film 87.
It should be evident from the foregoing that the invention
constitutes a significant advancement over the art in that by
selection of any of the above-described laminate wrapper
constructions, a moisture and air barrier can be produced which has
the advantage of durability, strength, and puncture and
tear-resistance without the loss of bi-axially elongation or
stretch and subsequent loss of circumferential stretch to the
finished duct.
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