Apparatus and method for a helically perforated wound duct

Abstract

The first roller dies will perforate, puncture the metal strip after the strip goes through the front guide. After the perforation the metal strip can then be corrugated. This is an improvement over punching the metal strip. Punching the metal, rotary punch, requires and extra step and leaves metal scrap, which is why punching metal for the first rolls would clog the machine and cause damage to the machine. The results of these tiny holes in the cylindrical duct help muffle the vibration and other noises from the motorized fan down the ductwork. The cylindrical perforated duct acts like a muffler. Air conditioning, bathroom exhaust fans, kitchen exhaust fans noise can me great reduced cheaply and efficiently. This perforated duct will be used with a vapor barrier and/or insulation.

Claims

1. An apparatus for producing a helically wound duct from a strip, the apparatus comprising: An elongated strip frame coupled to an elongated duct frame; A front guide coupled to said elongated strip frame for adjusting the tracking of the strip; A first position roller die to puncture, perforate the metal strip; A plurality of pair of corrugated roller dies coupled to said elongated strip frame for progressively corrugated the perforated strip; A finishing pair of corrugated roller dies couple to said elongated strip frame for creating a primary ascending leg in the primary edge of the strip and a secondary leg in the secondary edge of the strip; A strip guide couple to said elongated strip frame for adjusting the tracking of the strip; A plurality of helically disposed roller dies coupled to said elongated strip frame for creating a helically wound duct; A jointer guide couple to said elongated strip frame having a guide body extending between a exterior surface, an interior surface, a first side surface, a second side surface, a bottom surface and a top surface; guide shoulder extending from said interior surface of said guide body; A guide arm coupling to said guide shoulder for defining a guide channel between said interior surface of said guide body and said guide arm; Said exterior surface of said guide arm defining a primary leg guide surface Said primary leg guide surface maintains contact with the primary ascending leg the strip for defining primary alignment tool; Said external surface of said guide arm having a recessed secondary leg guide surface; Said recessed secondary leg guide surface maintains contact with the secondary descending leg of the strip for defining a secondary alignment tool; A front tucker having a radius finger for progressively bending the primary edge and the secondary edge of the strip; A rear tucker having a tapered edge for converging the primary edge and the secondary edge of the strip into said radius finger; Said primary alignment tool and said secondary alignment tool assist in aligning the primary ascending leg and the secondary descending leg of the strip before entering said front tucker and said rear tucker; A pair of knurl corrugated roller dies compressing and knurling said primary edge with the secondary edge of the strip for defining a continuous helically seam; Said helically wound strip and said continuously helically seam defining a cylindrical duct; A saw device coupled to said elongated duct frame for cutting said cylindrical duct to length

2. An apparatus for producing helically wound duct from a strip as set for in claim 1, wherein said top surface of said guide arm further includes a taper arm surface for directing secondary descending leg into said recessed secondary leg guide surface; and said top surface of said guide body includes a taper body surface for directing the secondary descending leg into said recessed secondary leg guide surface.

3. An apparatus fix producing a helically wound duct from a strip as set forth in claim 1 further including an expansion corrugated roller compressing against one of said plurality of helically disposed roller dies for maintaining a consistent diameter for said cylindrical duct.

4. A method for producing a helically wound duct from a metal strip. The methods Comprising the steps of adjusting the tracking of the strip with a front guide; the first roller dies perforate, puncture small holes in the strip before corrugation. Corrugating the perforated strip with a plurality of pair of corrugated roller dies; forming a primary ascending leg in the primary edge of the strip and a secondary descending leg in the secondary edge of the strip with a finishing pair of corrugated roller dies; Adjusting the tracking of the strip with a strip guide; Forming a helically wound strip with a plurality of helically disposed roller dies; Maintaining the primary ascending leg of the strip against a primary leg guide surface; Maintaining the secondary descending leg of the strip against a recessed secondary leg guide surface; Bending and interlocking the primary edge with the secondary edge of the strip with the front tucker and a rear tucker; Compressing and knurling the primary edge with the secondary edge of the strip with a pair of knurl corrugated roller dies; and cutting the helically wound duct with a saw.

5. A method for producing a helically wound duct, the methods comprising the steps of positioning a metal strip through a flattening roll; Adjusting the tracking of the strip with a read guide; Dipping the metal (copper, zinc both antimicrobial, or aluminum, steel) strip into the lubricating dip tank; Inserting the metal strip into a squeegee roller for removing excess fluid; Adjusting the tracking of the strip with a front guide; Using the first pair of roller dies that puncture, perforate the metal strip then corrugating the strip with polarity of pair of the corrugated roller dies; Forming a primary ascending leg in the primary edge of the strip and a secondary descending leg in the secondary edge of the strip with a finishing pair of corrugated roller dies; Adjusting the tracking of the strip with a strip guide; Forming a helically wound strip with a plurality of helically disposed roller dies; Compressing an expansion corrugated roller die against one of said plurality of helically disposed roller dies for maintaining a consistent diameter for said cylindrical duct; Maintaining the primary ascending leg of the strip against a primary leg guide surface; Maintaining the secondary descending leg of the strip against a recessed secondary leg guide surface;

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] For fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description taken in connection with the accompanying drawings in which:

[0025] FIG. 1 is a top view of an apparatus for producing a helically wound duct incorporating the present invention;

[0026] FIG. 2 front view of the helically wound duct machine

[0027] FIG. 3 is a rear isometric view of a jointer guide and a guide mounting block

[0028] FIG. 4 is a front isometric view of FIG. 3

[0029] FIG. 5 is a top view of FIG. 3

[0030] FIG. 6 is a front view of FIG. 3

[0031] FIG. 7 is a left side view of FIG. 3

[0032] FIG. 8 is a right side view of FIG. 3

[0033] FIG. 9 is an exploded view of FIG. 3

[0034] FIG. 10 is an exploded view of FIG. 4

[0035] FIG. 11 is a view similar to FIG. 4 illustrating the guide mounting block securing the jointer guide to an elongated strip frame wherein the jointer guide has a first positioned relative to the guide mounting block;

[0036] FIG. 12 is a view similar to FIG. 11 illustrating the jointer guide having a second positioned relative to the guide mounting block for permitting various coupling positions for the jointer guide relative to the elongated strip frame;

[0037] FIG. 13 is an enlarged portion of FIG. 2

[0038] FIG. 14 is an enlarged portion of FIG. 1

[0039] FIG. 15 is a sectional view along line 15-15 in FIG. 13

[0040] FIG. 15A is an enlarged portion of the FIG. 5 illustrating a finishing pair of corrugated roller dies for creating a primary ascending leg in a primary edge of the strip and secondary descending leg in the secondary edge of the strip;

[0041] FIG. 16 is a sectional view along line 16-16 in FIG. 13

[0042] FIG. 16A is an enlarged portion of FIG. 16 illustrating a primary leg guide surface of the jointer guide maintaining contact with the primary ascending leg of the strip for defining a primary alignment tool;

[0043] FIG. 16B is an enlarged portion of FIG. 16A;

[0044] FIG. 17 is a sectional view along line 17-17 in FIG. 13

[0045] FIG. 17A is an enlarged portion of FIG. 17 illustrating the front view of the jointer guide in relation to the rear tucker and front tucker;

[0046] FIG. 17B is an opposite directional view of FIG. 17A illustrating the front view of the jointer guide in relation to the rear tucker and the front tucker;

[0047] FIG. 17C is an enlarged portion of FIG. 17A;

[0048] FIG. 17D is an enlarged portion of FIG. 17B illustrating a recessed secondary leg guide surface maintaining contact with the secondary descending leg of the strip for defining a secondary alignment tool;

[0049] FIG. 18 is a sectional view along line 18-18 in FIG. 13;

[0050] FIG. 18A is an enlarged portion of FIG. 18 illustrating both the primary alignment tool and the secondary alignment tool aligning the primary ascending leg and the secondary descending leg and maintaining the primary ascending leg and secondary descending leg in close proximity before the primary ascending leg and the secondary descending leg engage the front tucker and the rear tucker;

[0051] FIG. 18B is an enlarged portion of FIG. 18A illustrating the primary ascending leg and the secondary descending leg beginning engagement with the front tucker and the rear tucker;

[0052] FIG. 19 is a sectional view along line 19-19 in FIG. 13;

[0053] FIG. 19A is an enlarged portion of FIG. 19 illustrating the front tucker progressively bending the primary edge and the secondary edge of the strip and the rear tucker converging the primary edge and the secondary edge of the strip into the front tucker;

[0054] FIG. 19B is an enlarged portion of 19A

[0055] FIG. 20 is a sectional view along line 20-20 in FIG. 13;

[0056] FIG. 20A is an enlarged portion of FIG. 20 illustrating a pair of knurl corrugated roller dies compressing the knurling the primary edge with the secondary edge of the strip for defining a continuous helically seam;

[0057] FIG. 20B is an enlarged portion of FIG. 20A;

[0058] FIG. 21 is a sectional view along line 21-21 in FIG. 13;

[0059] FIG. 21A is an enlarged portion of FIG. 21 illustrating the completed compression and knurling of the primary edge with the secondary edge of the strip for defining a continuous helically seam;

[0060] FIG. 21B is an enlarged portion of FIG. 21A

[0061] FIG. 22 is a sectional view along line 22-22 in FIG. 13 illustrating an expansion corrugated roller compressing against one of the plurality of helically disposed roller dies for maintaining a consistent diameter for the cylindrical duct;

[0062] FIG. 23 is a front isometric view of a cylindrical duct with perforation having been corrugated into a cylindrical duct. The metal being copper, zinc, for their antimicrobial properties in fighting mold and mildew growth, or steel or aluminum;

[0063] FIG. 24 is a side view of FIG. 23;

[0064] FIG. 25 is a side view of FIG. 24;

[0065] FIG. 26 is a sectional view along line 26-26 in FIG. 25 illustrating the perforated holes and continuous helically seam includes that construct the helically wound duct that uses an interlocking seam;

[0066] FIG. 28 is a top view of the metal strip after the first rolls perforate, puncture, but before the corrugating the metal strip.

[0067] FIG. 29 is an isometric view of the first roller dies that cut, perforate the metal strip;

[0068] FIG. 30 is a front view of the pair of the first roller dies that cut, perforate the metal strip;

DETAILED DISCUSSION

[0069] FIGS. 1-22 are various view of an apparatus for producing a helically wound duct 10 as shown in FIGS. 23-26 from one metal elongated strip frame 30 coupled to an elongated duct frame 32. A front guide 40 is coupled to the elongated strip frame 30 for adjusting the tracking of the strip 20. The first roller dies puncture, perforate the metal strip FIGS. 29-30. The metal strip can be made of copper, zinc for their antimicrobial properties, or steel, aluminum. The small holes will help muffle the noise down the ductwork where the motorized fan makes noise. A plurality of pair of corrugated roller dies 42 are coupled to the elongated strip frame 30 or progressively corrugating the strip 20. A finishing pair of corrugated roller dies 44 is coupled to the elongated strip frame 30 or progressively corrugating the strip 20. A finishing pair of corrugated roller dies 44 is coupled to the elongated strip frame 30 for creating a primary ascending leg 50 in the primary edge 26 of the strip 20 a secondary descending leg 52 in the secondary edge 28 of the strip 20.

[0070] A strip guide 60 is coupled to the elongated strip frame 30 for adjusting the tracking of the strip 20. A plurality of helically disposed roller dies 62 are coupled to the elongated strip frame 30 for creating a helically wound strip 64. A jointer guide 70 is coupled to the elongated strip frame 30 having a guide body. A guide shoulder 86 extends from the interior surface 76 of the guide body 72.

[0071] A guide arm 88 is coupled to the guide shoulder 86 for defining a guide channel 90 between the interior surface 76 of the guide body 94, a bottom surface 96 and a top surface 98. The exterior surface 92 of the guide arm 88 defines a primary leg guide surface 100. The primary leg guide surface 100 maintains contact with the primary ascending leg 50 of the strip 20 for defining a primary alignment tool 102. The external surface 92 of the guide arm 88 has a recessed secondary leg guide surface 104. The recessed secondary leg guide surface 104 maintains contact with the secondary descending leg 52 of the strip 20 for defining a secondary alignment tool 106.

[0072] A front tucker 110 has a radius finger 112 for progressively bending the primary edge 26 and the secondary edge 28 of the strip 20. A rear tucker 120 has a tapered edge 122 for converging the primary edge 26 and the secondary edge 28 of the strip 20 into the radius finger 112. The primary alignment tool 102 and the secondary edge 28 of the strip 20 into the radius finger 112. The primary alignment tool 102 and the secondary alignment tool 106 assist in aligning the primary ascending leg 50 and the secondary descending leg 52 of the strip 20 before entering the front tucker 110 and the rear tucker 120.

[0073] A pair of knurl corrugated roller dies 130 compressing and knurling the primary edge 26 with the secondary edge 28 of the strip 20 fix defining a continuous helically seam 132. The helically wound strip 64 and the continuously helically seam 132 define a cylindrical duct 134. A saw device 140 is coupled to the elongated duct frame 32 for cutting the cylindrical duct 134 to length.

[0074] The top surface 98 of the guide arm 88 further includes a taper arm surface 150 for directing the secondary descending leg 52 into the recessed secondary leg guide surface 104. The top surface 84 of the guide body 72 includes a taper body surface 152 for directing the secondary descending leg 52 into the recessed secondary leg guide surface 104. The jointer guide 70 may be secured to the elongated strip frame by a guide mounting block 154.

[0075] An expansion corrugated roller 60 compresses against one of plurality of helically disposed roller dies 62 for maintaining a consistent diameter for the cylindrical duct 134. The expansion corrugated roller 60 may be secured within the plurality of the helically disposed roller dies 62 by a magnetic couple 162 having a support rod 164 between the expansion corrugated roller 60 and the magnetic coupler 162.

[0076] The subject invention farther includes a method fix producing a helically wound duct 10. The method comprises the steps of positioning a metal strip 220 through a flattening role 300. The tracking of the strip 20 is adjusted with a rear guide 302. After the metal strip is dipped in the dip tank the metal strip is adjusted with the front guide 40. The strip is punctured, perforated with the first set of roller dies FIG. 29-30. The strip 20 is corrugated with a plurality of pair of corrugated roller dies 42. A primary ascending leg 50 in the primary edge 26 of the strip 20 and the secondary descending leg 52 in the secondary edge 28 of the strip 20 are formed with a finishing pair of corrugated roller dies 44. The tracking of the strip 20 is adjusted with a strip guide 60 a helically wound strip 64 is formed with a plurality of helically disposed roller dies 62. An expansion corrugated roller 160 is compressed against one of the plurality of helically disposed roller dies 62 fix maintaining a consistent diameter for the cylindrical duct 134. The primary ascending leg 50 of the strip 20 is maintained against a primary leg guide surface 100. The secondary descending leg 52 of the strip 20 is maintained against a recessed secondary leg guide surface 104. The primary edge is bent and interlocked with the secondary edge of the strip with the front tucker and the rear tucker. The primary edge 26 is compressed and knurled with the secondary edge 28 of the strip 20 with a pair of knurl corrugated roller dies 130. The helically wound duct 134 is cut with a saw 140.

[0077] Although the invention has been described in its preferred form with a degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and the numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention.