Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1999-08-09
2001-05-15
Yao, Sam Chuan (Department: 1733)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C052S302300, C285S284100, C285S424000, C138S149000, C138S162000, C138SDIG004
Reexamination Certificate
active
06231704
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention (Technical Field)
In the parent application, the invention is directed to methods and apparatus for forming, sizing and interconnecting duct work systems on site, including pre-insulated components and connectors for transporting fluids. More particularly, the invention is a device which combines a flat panel manufactured with an intermediate insulation layer sandwiched between two outside waterproof sheets, take-off apparatuses of two part construction and pre-insulted connector articles including matched transition components adapted to form an insulated duct system sized on-site.
In the present application, the invention is directed to an insulated air duct system for transferring a volume of fluid in a warm air heating and air conditioning system without employing external insulation or structural support members, otherwise required to support and insulate duct apparatus, comprising a plurality of lightweight duct modules in combination with take-off connectors, each formed on-site from rigid fibrous glass board (RFGB) with reinforced facing each duct module comprising structural support means for providing inherent structural strength to each duct module and including one or more insulated fitting devices for coupling air duct system components together.
2. Background Art
There is a well recognized need for ease of forming air duct work on site, particularly duct work requiring insulation installed in residential buildings. Applicant is aware of prior art devices that have attempted to solve this need by employing a duct board of sandwiched construction for constructing ducts.
In U.S. Pat. No. 5,219,403 to Murphy, there is shown a distribution box, and a rectangular duct line having an intermediate foam core sandwiched between inner and outer plastic layers. Corner molding slots are provided to connect two adjacent duct board walls along its length. The limitations of Murphy result from the inherent structural weakness of foam core duct board walls requiring additional exterior structural support resulting in difficult and slow assembly, as well as structurally weak corner joints. Also Murphy does not teach a simple and effective means of joining duct lines, nor internally insulated couplings.
The present invention overcomes the limitations expressed above of the prior technology, by employing the advantageous characteristics of an insulated air duct system comprising a plurality of lightweight, insulated duct modules in combination with take-off connectors, each duct module comprising duct walls joined by corner members with comprising rigid fibrous glass (RFGB) with reinforced facing, formed on-site, having inherent structural strength such that each duct module is self supporting and including one or insulated improved fitting devices for joining duct modules and for coupling insulated components.
SUMMARY OF THE INVENTION
The present invention is directed to an insulated air duct apparatus including insulated duct modules and associated insulated fitting devices for transferring a volume of fluid in a warm air heating and air conditioning installation without employing external insulation or structural support members, otherwise required to support and insulate duct apparatus. In particular the present invention comprises a plurality of lightweight duct modules in combination with take-off devices (transition means) for joining such modules, each duct module comprising duct walls joined by corner members wherein said duct walls and take-off devices (transition means) comprise rigid fibrous glass (RFGB) with reinforced facing having inherent structural strength such that each duct module is self supporting. This invention also includes one or more associated rigid fibrous glass fittings having internal insulation means for coupling air duct system components together. By eliminating duct work components, as provided by prior technology, employing external insulation or structural support members, installation is greatly simplified. The duct apparatus is easy to use as it comprises one or more lightweight duct modules and includes one or more associated insulated fitting devices for joining insulated modules and for coupling insulated components.
Each duct module is made up of four panel members comprising a plurality of duct walls of lightweight rigid fibrous glass (RFGB) with reinforced facing cut to size. These walls are joined together by associated structural corner members of plastic material typically constructed of ABS plastic cut to size for joining adjoining duct walls to form a light weight, rigid, self-supporting duct module. Also provided is a simple method of providing access doors in the duct for permitting access to interior spaces as well as fitting devices permitting fluid to communicate between duct system components.
Also included are insulated fitting devices for connecting said duct module to component members including take off apparatus for associating with said access means for cooperating with an inner facing of a duct wall. The take-off apparatus (transition means) includes two parts, one part female having a flange, one part male having a flange. The female part would be mounted on the inner surface of a duct wall with adhesive means (ABS plastic glue) applied to the inside surface of the flange for contacting the inner facing of the duct wall, and the male part would be mounted on the outer surface of a duct wall with adhesive means (ABS plastic glue applied to the outside). Further included are duct modules comprising secondary duct means including one or more access members for communication with a tubular conduit means.
The invention is further directed to an air duct work system comprising air duct work as well as transition fitting components cut on-site from pre formed sheets of rigid fibrous glass board (RFGB) with reinforced facing such as reinforced aluminum foil/kraft (FRK) facing for forming thermally and acoustically insulated air duct system. Such (RFGB) may be used to fabricate on-site air ductwork for heating, cooling and dual temperatures systems operating up to 5,000 FPM, plus or minus 2 inches w.g.(500 Pa) static pressure, 250 degrees F.; (121 degrees C.) internal air temperatures. The Fiberglas duct board has a stiffness defined by flexural rigidity. A duct board of 1½″ provides a combination of structural rigidity as well as superior thermal value. In the present invention, panels are cut from a large sheet consisting of pre formed insulated material and connected to pre-insulated components on a construction site. This is a major improvement over the current practice of having sheet metal duct work prepared off-site which must be insulated on site after or during installation.
Further, each transition component connects to a plurality of duct sub systems. Also, connector articles are employed to hold the sides of the duct together along its length. In the specific arrangement of the invention the transition components connect to the main duct by gluing into the edges of the main duct assemblies.
The present invention is also directed to a method of installing an air duct work system including the employing a novel single stage method of constructing air duct work as well as transition fitting components from pre formed sheets of rigid fibrous glass board (RFGB) with reinforced facing such as reinforced aluminum foil/kraft (FRK) facing for forming thermally and acoustically insulated air duct system.
An advantage of the present invention is that access hole locations are no longer critical, as holes are cut into duct after a main trunk is completely installed, whereby a tool can easily cut holes in the top of the duct or in the sides in confined spaces. A further advantage is that duct work hangers do not penetrate the vapor barrier causing sweating of exposed metal parts in the cooling mode. Yet a further advantage is that all duct work insulation is completely sealed against moisture and fiberglass fibers cannot become airborne within the duct, unlike me
Kahrl Esq Thomas A.
Yao Sam Chuan
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