Method and apparatus for attaching flange portions to ducts

Abstract

A flange to be assembled to a duct member includes a plurality of pre-fabricated apertures or areas of weakened wall strength for receiving fasteners to assemble the flange to the end of a duct member. The apertures may be spaced apart such that the fasteners can be inserted at regular intervals along the length of the flange and the length of the end of the duct member.

Claims

1. A duct member panel flange, comprising: a first wall member; a second wall member, which wall members are configured to receive a duct member panel there between, wherein at least a portion of the first wall member and at least a portion of the second wall member extend substantially parallel one another; an intermediate member connected to the first and second wall members; and a plurality of first pre-fabricated apertures disposed in the first wall member, and a plurality of second pre-fabricated apertures disposed in the second wall member, wherein the first pre-fabricated apertures are substantially aligned with the second pre-fabricated apertures.

2. The flange of claim 1, wherein the intermediate member includes a rib disposed proximate the first wall member.

3. The flange of claim 2, wherein the intermediate member includes a first flange panel connected to a second flange panel, and first flange panel includes the rib.

4. The flange of claim 3, wherein the rib extends outwardly from the first flange panel in a direction that is substantially parallel to the first wall member, and is spaced apart from the first wall member.

5. The flange of claim 1, wherein the plurality of first pre-fabricated apertures are disposed in the portion of the first wall member that is substantially parallel the second wall member, and the plurality of second pre-fabricated apertures are disposed in the portion of the second wall member that is substantially parallel the first wall member.

6. The flange of claim 1, wherein the first pre-fabricated apertures and the second pre-fabricated apertures are configured the same.

7. The flange of claim 1, wherein the plurality of first pre-fabricated fastener entry areas are disposed in the portion of the first wall member that is substantially parallel the second wall member, and the plurality of second pre-fabricated fastener entry areas are disposed in the portion of the second wall member that is substantially parallel the first wall member.

8. A method for manufacturing a duct member panel flange, comprising: forming a flange into a unitary configuration that includes a first wall member, a second wall member, and an intermediate member connected to the first and second wall members, which intermediate member includes a rib disposed proximate the first wall member, wherein at least a portion of the first wall member and at least a portion of the second wall member extend substantially parallel one another; forming a plurality of first pre-fabricated apertures within the first wall member; and forming a plurality of second pre-fabricated apertures disposed in the second wall member, wherein the first pre-fabricated apertures are substantially aligned with the second pre-fabricated apertures; wherein the plurality of first pre-fabricated apertures are disposed in the portion of the first wall member that is substantially parallel the second wall member, and the plurality of second pre-fabricated apertures are disposed in the portion of the second wall member that is substantially parallel the first wall member.

9. The method of claim 8, wherein the step of forming the flange into the unitary configuration includes forming the intermediate member to include a first flange panel connected to a second flange panel, and the rib extending outwardly from first flange panel.

10. The method of 9, wherein the step of forming the flange into the unitary configuration includes forming the rib to extend outwardly from the first flange panel in a direction that is substantially parallel to the first wall member, and is spaced apart from the first wall member.

11. A duct member panel flange, comprising: a first wall member; a second wall member, which wall members are configured to receive a duct member panel there between, wherein at least a portion of the first wall member and at least a portion of the second wall member extend substantially parallel one another; an intermediate member connected to the first and second wall members; and a plurality of first pre-fabricated fastener entry areas in the first wall member, and a plurality of second pre-fabricated fastener entry areas in the second wall member, wherein the first pre-fabricated fastener entry areas are substantially aligned with the second pre-fabricated fastener entry areas.

12. The flange of claim 11, wherein the first pre-fabricated fastener entry areas are apertures or indentations, or some combination thereof.

13. The flange of claim 11, wherein the second pre-fabricated fastener entry areas are apertures or indentations, or some combination thereof.

14. The flange of claim 11, wherein the intermediate member includes a rib disposed proximate the first wall member.

15. The flange of claim 14, wherein the intermediate member includes a first flange panel connected to a second flange panel, and first flange panel includes the rib.

16. The flange of claim 15, wherein the rib extends outwardly from the first flange panel in a direction that is substantially parallel to the first wall member, and is spaced apart from the first wall member.

17. A duct member panel flange, comprising: a first wall member; a second wall member, which wall members are configured to receive a duct member panel there between, wherein at least a portion of the first wall member and at least a portion of the second wall member extend substantially parallel one another; an intermediate member connected to the first and second wall members; and a plurality of pre-fabricated fastener entry areas in at least one of the first wall member or the second wall member.

18. The flange of claim 17, wherein the pre-fabricated fastener entry areas are apertures or indentations, or some combination thereof.

19. The flange of claim 17, wherein the intermediate member includes a first flange panel connected to a second flange panel, wherein at least a portion of the first flange panel and at least a portion of the second flange panel extend substantially parallel one another, and a plurality of pre-fabricated fastener entry areas disposed in at least one of the first flange panel or the second flange panel.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) Preferred embodiments of the invention are disclosed hereinbelow with reference to the drawings.

(2) FIG. 1 is a top front left side perspective view of a flange and end portion of a duct member in the prior art.

(3) FIG. 2 is a left side cross-sectional view of the flange and end portion of FIG. 1, prior to assembly.

(4) FIG. 3 is a left side cross-sectional view of the assembled flange and end portion.

(5) FIG. 4 is a bottom top rear perspective view of the assembled flange and end portion.

(6) FIG. 5 is a left side cross-sectional view of an improperly assembled flange and end portion.

(7) FIG. 6 is a bottom rear perspective view of the improperly assembled flange and end portion of FIG. 5.

(8) FIG. 7 is a top rear left side perspective view of a flange according to the present invention.

(9) FIG. 8 is a front elevational view of the flange of FIG. 7 along lines 8-8 in FIG. 7.

(10) FIGS. 9-13 are top front left side views of enlarged section of the flange of FIGS. 7-8 illustrating alternative embodiments of an aperture of the present invention.

(11) FIG. 14 is a left side cross-sectional view of the flange of FIGS. 7-8 adjacent to an end portion of a duct member prior to assembly.

(12) FIG. 15 is a left side cross-sectional view of the assembled end portion and flange of FIGS. 7-8.

(13) FIG. 16 is top rear elevational view of the assembled flange and end portion of FIG. 12.

(14) FIG. 17 is a top front perspective view of a pair of ducts having flange of the present invention mounted thereon for joining the ducts.

DETAILED DESCRIPTION OF THE INVENTION

(15) The prior art of FIGS. 1-6, having been previously generally described, FIGS. 7-17 describe a flange 34 and portions thereof according to the present invention provided to be assembled to an end portion 12 of a duct member.

(16) As shown in FIG. 7, an example embodiment of the present invention illustrates a flange 34 including at least a front wall member 36 (also referred to herein as an outer wall member 36) configured in a manner known in the art for joining adjacent flanges 34 together. For example, lateral ends of the front wall member 36 of the flange 34 may include corner sections and/or apertures known in the art, such as shown in FIG. 17 and described in greater detail in U.S. Pat. Nos. 4,288,115; 4,564,227; 4,725,083; 5,103,872; and 5,621,956, which are incorporated herein by reference. Such corner sections and/or apertures permit the flanges 34 secured to duct members to be assembled to join such duct members together in a manner known in the art. It is to be understood that the flange 34 may be of any size, shape, or configuration, such as flanges known in the art.

(17) In the example embodiment of the present invention shown in FIG. 7, the flange 34 also includes a rear wall member 38 (also referred to herein as an inner wall member 38), with the wall members 36, 38 joined by an intermediate member 40. The wall members 36, 38 of the flange 34 are adapted, as shown in FIG. 14, to receive an end portion 12 of a duct member between the wall members 36, 38, and with the front wall member 36 abutting the exterior surfaces of the end portion 12, such that the front wall member 36 is externally exposed. As can be seen from FIG. 7, the intermediate member 40 includes an inner flange panel 41 and an outer flange panel 43. The inner flange panel 41 and outer flange panel 43 are connected to one another. A rib 45 is formed in the inner flange panel 41. The rib 45 is disposed proximate the rear wall member 38, and is separated from the rear wall member 38 by a distance substantially equal to the thickness of the duct member (e.g., see FIGS. 14 and 15). The proximity of the rib 45 to the rear wall member 38 prevents deflection of the flange 34 and thus enables a secure fastening of the flange 34 to the end portion 12 of the duct member. The inner flange panel 41 and outer flange panel 43 are configured such that the flange 34 is shaped for receiving corner pieces 58 (e.g., see FIG. 17).

(18) The flange 34 may be fabricated from metal, such as aluminum, stainless steel, or other known metals or alloys, by methods known in the art, such as by stamping.

(19) In the example embodiment, the flange 34 shown in FIG. 7 includes fastener entry areas 42 on at least the front wall member 36. Alternatively, the flange 34 may also include such fastener entry areas 44 on the rear wall member 38, as illustrated in the cut-away portion of the front wall member 36 in FIG. 7, such that the fastener entry areas 42, 44 are complementary; that is, each fastener entry area 42 on the front wall member 36 is substantially aligned with a respective fastener entry area 44 on the rear wall member 38.

(20) Accordingly, referring to FIG. 14, when an end portion 12 of a duct member is positioned in the gap between the wall members 36, 38, a pair of complementary fastener entry areas 42, 44 are positioned at substantially identical locations on opposite sides of the end portion 12.

(21) As shown in FIGS. 7-8, a plurality of fastener entry areas 42, 44 are provided along the length of the flange 34 on each of the wall members 36, 38, respectively. In an example embodiment shown in FIG. 8, the plurality of fastener entry areas 42 are regularly spaced apart at predetermined equal distances along the length of the front wall member 36 of the flange 34. Similarly, the plurality of fastener entry areas 44 are regularly spaced apart at predetermined equal distances along the length of the rear wall member 38 of the flange 34.

(22) In addition, the fastener entry areas 42, 44 may be spaced apart at predetermined metric distances, such as along one-centimeter intervals, or by predetermined English units, such as along one-inch intervals. The predetermined spacing permits an assembler to readily site one or more fastener entry areas 42, 44 at any selected distance, for example, from the corner of a duct, in order to meet predetermined specifications for assembly of the ducts. For example, an assembly specification may require a fastener 20 to be spaced at about two inches from a corner of a duct, so the flange 34 may be positioned along the end portion 12 to site a pair of fastener entry areas 42, 44 at two inches from the corner.

(23) Referring to FIG. 9, in one example embodiment, each of the fastener entry areas 42, 44 on the wall members 36, 38 may be an aperture, forming a through hole 46, such as shown, for example, passing through the front wall member 36, with the through holes 46 being pre-fabricated apertures in the wall members 36, 38 for receiving fasteners to assemble the flange to the end of a duct member. The through holes 46 may be regularly spaced apart, as shown in FIG. 8, such that at least one fastener 20 can be inserted through the holes 46 at regular intervals along the length of the flange 34 and the length of the end portion 12 of the duct member.

(24) Referring to FIG. 10, in another example embodiment, each of the fastener entry areas 42, 44 on the wall members 36, 38 may be an indentation 48, such as shown, for example, entering but not completely passing through the rear wall member 38, with the indentations 48 being pre-fabricated dimples or weakened points in the wall members 36, 38 for receiving fasteners to assemble the flange to the end of a duct member. The indentations 48 may be regularly spaced apart, as shown in FIG. 8, such that at least one fastener 20 can be inserted through the indentations 48 at regular intervals along the length of the flange 34 and the length of the end portion 12 of the duct member.

(25) In another example, embodiment, the fastener entry areas 42 on the front wall member 36 may be through holes 46 as in FIG. 9, while the fastener entry areas 44 on the rear wall member 38 may be indentations 48 as in FIG. 10, or vice versa, to facilitate entry and passing through of the fastener 20 to assemble the flange 34 to the end portion 12, as described herein.

(26) It is to be understood that the fastener entry areas 42, 44 on the wall members 36, 38 may be through holes or indentations of any shape, and not limited to circular holes 46 or indentations 48, as shown in the example embodiments in FIGS. 9-10. For example, in alternative embodiments shown in FIGS. 11-13, the fastener entry areas may be slots 50 forming an elongated hole having, for example, rounded ends, or may be a square hole 52 or a rectangular hole or slot 54. Such holes 50-54 may instead be replaced by indentations of similar shape. In the form of circular-ended slots 50 or rectangular slots 54 shown in FIGS. 11 and 13, respectively, the fastener entry areas 42, 44 facilitate entry of the fastener 20 therethrough even though the complementary fastener entry areas 42, 44 on opposite sides of the end portion 12 may not be perfectly aligned.

(27) Referring to FIG. 14, during the mounting operation of the flange 34 to the end section 12, the flange 34 is positioned about the end portion 12, and with the fastener entry areas 42, 44 on either side of the end portion 12, with the fastener 20 oriented for insertion by the tool 22, and with the fastener entry areas 42, 44 being of any size and shape such as the shapes shown in FIGS. 9-13, and any configuration, such as any of the holes in FIGS. 9 and 11-13, being of any size, or an indentation of any size or shape such as the indentation 48 shown in FIG. 10. In the example shown in FIG. 14, the fastener entry areas 42, 44 are through holes in each respective wall member 36, 38, such as the holes 46 shown in FIG. 9. Alternatively, it is to be understood that the fastener entry areas 42, 44 on either side of the end portion 12 may be the indentations 48 shown in FIG. 10, or may also be a combination of through holes and indentations shown in FIGS. 9-13.

(28) With the fastener 20 positioned as shown in FIG. 14, the tool 22 more easily inserts the fastener 20 through the fastener entry areas 42, 44 and through the section of the end portion 12 between the fastener entry areas 42, 44 to form the assembled flange and end section shown in FIGS. 15-17.

(29) By providing such fastener entry areas 42; 44, assembly of the final configuration shown in FIGS. 15-17 is performed more quickly, more effectively, and with less force and torque required by the tool 22. In addition, since the rear wall member 38 has a complementary fastener entry area 44 ready to receive the fastener 20 passing through the adjacent region of the end portion 12, there is little or no chance for the fastener 20 to apply force to the rear wall member 38, and so the rear wall member 38 will not be pushed out in an improper configuration as shown in FIGS. 5-6.

(30) Accordingly. the final configuration of the flange 34 and the end portion 12 of the duct member may be assembled more rapidly and efficiently in the field with fewer or no mistakes requiring remedy. In effect, the effort to create the fastener entry areas 42, 44 is performed during fabrication of the flange 34, long before use and assembly in the field, so assemblers may complete their work more efficiently. As shown in FIG. 17, the combination of the flange 34 mounted to the end portion 12 of a duct member 56 can have corner pieces 58 mounted in adjoining flanges 34 on the corners of the ends of the duct member 56, in a manner similar to the use of corner pieces in the prior art. Pairs of duct members 56 having such mounted flanges 34 can then be assembled together, for example, by fastening complementary corner pieces 58 together.

(31) In addition, since the fastener entry areas 42, 44 are regularly spaced along the length of the flange 34, the duct assembler in the field can readily locate multiple areas 42, 44 for inserting a predetermined number of fasteners 20 at any prescribed or required distance, for example, relative to a corner section of the duct member.

(32) The material strength of the flange 34 is also maintained, since the fastener entry areas 42, 44 are relatively small in size compared to the overall dimensions of the flange 34. In addition, insertion of the fastener 20 through the flange 34 of the present invention will have less or no debris from the insertion point positioned between the flange 34 and the end portion 12, and so the assembled flange 34 and end portion 12 of FIGS. 15-17 will have a tighter fit compared to the assembly of the prior art shown in FIGS. 3-4.

(33) While the preferred embodiment of the present invention has been shown and described herein, it will be obvious that such embodiment is provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the invention herein. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims.