PRE-FABRICATED GREASE DUCT SYSTEM

Abstract

The present double walled grease duct includes a tubular outer shell surrounding a tubular inner liner, wherein a spacer is positioned perpendicular to the walls of the outer shell and the inner liner. The spacer can include a plurality of vertical metal strips extend from a top edge of the spacer to the bottom edge of the spacer, wherein the top edge of the spacer contacts the walls of the outer shell and wherein the bottom edge of the spacer contacts the walls of the inner liner. The metal strips resist the different rates of thermal expansion between the outer shell and inner liner ultimately preventing the collapse of the inner liner under pressure from thermal expansion.

Claims

1. A double walled grease duct comprising: an outer shell including an outer tubular body having an outer first end and an outer second end; an inner liner including an inner tubular body having an inner first end and an inner second end, wherein the inner liner has a cross-sectional area less than a cross-sectional area of the outer liner, wherein at least a portion of the inner liner is positioned within the outer shell; and a spacer rigidly attaching the outer shell to the inner liner, the spacer including a planar body including an outer spacer edge and an inner spacer edge, each edge spanning between a first spacer end and a second spacer end of the planar body, wherein the outer edge contacts the outer shell, wherein the inner edge contacts the inner liner, wherein the spacer includes a plurality of metal strips surrounding a plurality of perforations, and wherein at least one line drawn along the planar body from the first spacer end to the second spacer end and parallel to each of the inner spacer edge and the outer spacer edge passes along lengths of metal along the plurality of metal strips and lengths of voids along the plurality of perforations, wherein a cumulative length of metal along which the at least one line passes is less than a cumulative length of voids along which the at least one line passes.

2. The double walled grease duct of claim 1, wherein the perforations are filled with insulation.

3. The double walled grease duct of claim 1, wherein the planar body of the spacer includes notches in the inner spacer edge, wherein the notches are notch voids in the inner spacer edge, wherein when the spacer is bent around the outer surface of the inner tubular body, a first portion of the planar body overlaps a second portion of the planar body.

4. The double walled grease duct of claim 1, wherein the inner liner has a higher rate of thermal expansion than the outer shell.

5. The double walled grease duct of claim 1, wherein the metal strips have a width between, and including, 0.5 inch to 1 inch.

6. The double walled grease duct of claim 1, wherein the space between the outer tubular body and the inner tubular body is at least partially filled with ceramic fiber insulation.

7. The double walled grease duct of claim 1, wherein the inner first end of the inner liner extends outside of the outer first end, and wherein the inner second end of the inner liner extends outside of the outer second end.

8. The double walled grease duct of claim 1, further comprising a flange outwardly extending from a perimeter of the inner first end, the inner second end, or combinations thereof.

9. The double walled grease duct of claim 8, wherein the width of the flange is between, and including, 0.5 inch to 1.5 inches.

10. The double walled grease duct of claim 8, wherein the flange is connected to a second grease duct.

11. The double walled grease duct of claim 1, wherein each metal strip has a width between adjacent perforations of between about 0.1 inches and 3 inches.

12. The double walled grease duct of claim 11, wherein each metal strip has a width between adjacent perforations of between about 0.5 inches and 2 inches.

13. The double walled grease duct of claim 12, wherein each metal strip has a width between adjacent perforations of between about 0.5 inches and 1 inches.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.

[0019] FIG. 1 is a perspective view of an example of the double walled straight rectangular grease duct section.

[0020] FIG. 2 is a front elevational view of an example of the double walled rectangular Reduced 90 degree Tee grease duct section.

[0021] FIG. 3 is a side view of an example of the double walled rectangular grease duct section.

[0022] FIG. 4 is a front elevation view of an example spacer disclosed herein.

[0023] FIG. 5 is an enlarged view of an example of a corner of the spacer disclosed herein.

[0024] FIG. 6 is the backside view of an example of a corner of the spacer disclosed herein.

[0025] FIG. 7 is a flat pattern view of an example of the spacer disclosed herein.

[0026] FIG. 8 is a front elevational view of an example flange disclosed herein.

[0027] FIG. 9 is a flat pattern view of an example of the flange disclosed herein.

[0028] FIG. 10 is a perspective view of an example of a 45-degree tee grease duct.

[0029] FIG. 11 is a perspective view of an example of a 90-degree tee grease duct.

[0030] FIG. 12 is a perspective view of an example of a 90-degree wye grease duct.

[0031] FIG. 13 is a perspective view of an example of a 90-degree wye grease duct.

[0032] FIGS. 14a-14b are perspective views of examples of an end-cap for a double walled grease duct.

[0033] FIG. 15 is a perspective view of a fan adaptor.

DETAILED DESCRIPTION OF THE INVENTION

[0034] FIG. 1 illustrates an example of a manufactured double walled straight rectangular grease duct 100. As shown in FIG. 1, the straight grease duct 100 includes an inner liner 102, an outer shell 104, a spacer 106, and a flange 108. The inner liner 102 includes an inner end 102c (see FIG. 3) extends out past an outer end 104a (see FIG. 3) of the outer shell 104, which allows room for the installer's hands to work during field assembly. For example, the inner liner 102 can be composed of an internal portion 102a that can be completely encompassed by the outer shell 104, and an external portion of an external inner liner 102b that can protrude out from the outer shell 104.

[0035] The straight grease duct 100 can have a section length 110, wherein the section length 110 can be between and including 10-80 inches, e.g., 18 inches, 30 inches, 42 inches, or 60 inches, or any suitable length.

[0036] The inner liner 102 can have an inside width 112 and an inside height 114. In an example, the inside width 112 and inside height 114 can have a minimum length of 4 inches, a maximum length of 48 inches, and a maximum interior cross-section area of 1300 square inches (e.g., 1296 square inches). Further, in an example, the inner liner 102 can have a maximum inside width 112 to inside height 114 ratio of 6:1.

[0037] The liner extender 102b extends beyond the outer shell and can have a length between, and including, 0.5 inches to 10 inches, for example, 1 inch, 3 inches, 5 inches, 6 inches, among others.

[0038] The outer shell 104 can have an outside width 116 and an outside height 118. The outside width 116 and outside height 118 can be greater than the inside width 112 and inside height 114, respectively. In an example, the length of the outer shell 104 can be 6 to 8 inches longer than the length of the inner liner 102. The size difference between the dimensions of the inner liner 102 and outer shell 104 results in an annular space between the inner liner 102 and outer shell 104.

[0039] The spacer 106 lies perpendicular between the inner liner 102 and outer shell 104 and sits flush with the edge of the outer shell 104 and the inner liner 102 can extend past the spacer 106.

[0040] The inner liner 102, outer shell 104, spacer 106, and flange 108 can individually be made of any suitable material. In an example, the inner liner 102, outer shell 104, spacer 106, and flange 108 include metals that have a metal gauge value that can withstand the high temperatures generated by the possible ignition and combustion of built up layers of grease within the inner liner 102 of an improperly maintained grease duct.

[0041] The inner liner 102 can be constructed of stainless steel with a minimum gauge value of 20 and/or mild carbon steel with a minimum gauge value of 16. In an example, the outer shell 104 can include an outside width 116 and outside height 118 of less than or equal to 36 inches, wherein the outer shell 104 can be constructed 24-gauge aluminized steel, galvanized steel, or stainless steel. The outer shell 104 with an outside width 116 or outside height 118 greater than 36 inches can be constructed of at least 20-gauge aluminized steel, galvanized steel, or stainless steel.

[0042] The spacer 106 can be constructed from 20-gauge to 18-gauge stainless steel. The flange 108 can be constructed from at least 11 gauge mild steel, aluminized steel, galvanized steel, or stainless steel.

[0043] FIG. 3 illustrates an example wherein the external inner liner 102b protrudes out of the outer shell 104. As seen in the figure, the flange 108 is MIG welded to the end of the external inner liner 102b. However, MIG welding is only one of any number of welding methods by which the flange 108 can be attached to external inner liner 102b.

[0044] As shown in FIG. 2, the annular space between the inner liner and outer shell is filled with thick layers of ceramic fiber insulation 111 (e.g., high-temperature ceramic fiber insulation). The ceramic fiber insulation 111 can be alkaline earth silicate fiber insulation and can have a density of 10 pounds per cubic foot. However, the density of the insulation can vary depending on the use requirements for a given venting system installation. For example, a range of densities between 8-12 pounds is contemplated, with different insulation densities potentially being used within different portions of a given venting system installation to save on costs, aid in weight balancing, etc.

[0045] In an example, the annular space is filled with insulation 111 to wrap the inner liner 102, for example, in multiple (e.g., 3) layers, of nominal 1-inch thick insulation within the entire annular space before placing the outer shell 104 over the inner liner 102. For example, the annular space between the inner liner 102 and outer shell 104 is 3 or 4-inches, the inner liner 102 should be wrapped with three 1-inch layers of insulation 111. The annular space can be either 3 inches or 4 inches wide. In an example, 3 wraps of 1″ nominal thickness ceramic fiber insulation is used.

[0046] FIG. 4 illustrates an example of the spacer 106. As seen in FIG. 4, the spacer 106 includes sides 120, 122, 124, and 126. The spacer 106 also includes one or more perforations 130. The perforations are voids and/or openings within the planar body of the spacer. The perforations may be one of many shapes, including, but not limited to ovals, circles squares, rectangles, pentagons, and/or hexagons.

[0047] As shown in FIG. 4, the perforations 130 create vertical metal strips 132 between the perforations 130. The metal strips 132 traverse between the two edges of the spacer. In an example, one perforation is between two metal strips. The metal strips 130 act as a heat sink by reducing the amount of heat transferred between the inner liner 102 and out shell 104. During operation of the grease duct system, the metal of the inner liner 102 can reach extreme temperatures (approximately 2000 degrees Fahrenheit). The metal of the outer shell 104, while not as hot as the inner liner 102, can also reach high temperatures (approximately 400 degrees Fahrenheit). Therefore, in order to prevent failure (e.g., a fire), the present device reduces the amount of heat transfer between the inner liner 102 and outer shell 104. The metal strips 132 can be narrow in width to allow the insulation 111 to absorb the heat away from the metal. For example, the perforations can be filled at least partially with insulation. The width of the metal strips 132 can be between, and including, 0.1 inches to 3 inches, 0.5 inch to 2 inches, 0.5 inch to 1 inch, among others.

[0048] Additionally, the narrow metal strips 132 can have limited resistive strength to resist the different rates of thermal expansion between the inner liner 102 and outer shell 104. As previously discussed, both the inner liner 102 and outer shell 104 can reach high temperatures during operation. However, the inner liner 102 has a higher rate of thermal expansion than the outer shell 104 because the inner liner 102 reaches temperatures higher than the outer shell 104. The metal strips 132 resist the difference rates of thermal expansion between the inner liner 102 and outer shell 104 by functioning as expansion joints.

[0049] If the inner liner 102 was rigidly attached to the outer shell 104 with a spacer 106 that did not include perforations 130, the inner liner 102 may collapse during operation due to the thermal expansion difference between the inner liner 102 and outer shell 104. For example, the thermal expansion difference may be so great that it applies too much pressure on the inner liner 102, weakening the inner liner 102, and causing the inner liner 102 to collapse on itself, possibly leading to a fire. However, with inclusion of perforations 130, the metal strips 132 can resist the different rates of thermal expansion and prevent the inner liner 102 from collapsing.

[0050] Spacer 106 also includes overlap areas 128a, 128b, 128c, and 128d are areas where one side of the spacer overlaps another perpendicular side of the spacer 106. For example, as seen in FIG. 4, in overlap area 128d, side 126 overlaps side 120. The overlap areas may also include one or more spot-weld locations 134, which is where the spacer 106 is welded to the inner liner 102, as shown in FIG. 5. The spacer 106 may be resistance welded into place between the inner liner 102 and outer shell 104. Although other welding methods can be used.

[0051] FIG. 6 illustrates the backside of the spacer 106 shown in FIGS. 2 and 4. The backside of the spacer 106 includes roll formed flange 136a and overhang 136b. The roll formed flanges 136a and overhang 136b allow the spacer 106 to have a tighter fit when installed and attached to the inner liner 102. The roll formed flange also provides a flat area to weld.

[0052] FIG. 7 illustrates the spacer 106 as it would look if it were laid out at 180 degrees on a flat surface. The spacer 106 can include notches 150a, 150b, and 150c, and 150d, bend lines 152, and overlap areas 154. Each side of the spacer can be folded along the notch to create the rectangular spacer 104 illustrated in FIG. 4. For example, side 122 can be folded along notch 150a such that it is perpendicular to side 120. The notches may be cut at between, and including, 30 degrees to 55 degrees, for example, 45 degrees.

[0053] As seen in FIG. 7, the spacer 106 may also include bend lines 152. The bend lines 152 allow the sides of the spacer 106 to be bent so as to create the overhangs 136a and 136b seen in FIG. 6.

[0054] FIG. 8 is an example of the mating side of the flange 108 shown in FIGS. 1 and 2. The mating side of the flange 108 is capable of being attached to the mating face of a second grease duct. As seen in FIG. 8, the flange 108 includes sides 160, 162, 164, and 166 and slotted bolt holes 168. The flange 108 has a width 170. The width 170 can be between, and including, 0.5 inch to 4 inches, 0.5 inch to 2 inches, 0.5 to 1.5 inches, for example, 1 inch.

[0055] During installation of the flange 108, fasteners are inserted into the bolt holes 168 to attach the flange 108 to the flange of another grease duct fitting or component. It is preferred that the bolts holes be spaced no more than 6-inches apart. The mating face of the flange 108 is flush with the front-end of the inner liner.

[0056] Upon installation, a rectangular flange can be capable of being rotated 180 degrees and match the mating flange of an adjoining rectangular grease duct and that a square flange be capable being rotated 90 degrees and match the mating flange of an adjoining square grease duct.

[0057] FIG. 9 illustrates the flange 108 as it would look if it were laid out at 180 degrees on a flat surface. The flange can be folded into four sides 160, 162, 164, and 168. Similar to spacer 106, flange 108 includes notches 172a, 172b, 172c, and 172d. Each side of the flange 108 can fold along its corresponding notch to create a rectangle. For example, side 160 can fold along notch 172a so that side 160 is perpendicular to side 162.

[0058] The present device can be any suitable shape and configuration. For example, various types of ducts are generally used for construction purposes, including maneuvering around walls and going through ceilings, as shown in FIGS. 10-13. For example, in order to connect a horizontal portion of the grease duct system to a vertical portion of the grease duct system, a one or more 90-degree tee, as shown in FIG. 11 may be used. As shown in FIG. 12-13, the device can include more than one elbows.

[0059] FIGS. 14a to 14b illustrate a grease duct end cap 700 that can be installed on any of the grease duct sections previously presented. The end cap includes a drain pipe 200 that is used to discharge grease out of the ducts into a reservoir. FIG. 15 illustrates a fan hood transition section of a grease duct system. The fan hood transition section 800 is connected, via the flange, to a fan hood used to exhaust the grease laden air present in the kitchen cooking area, out to the atmosphere.

[0060] The various duct sections can be joined together via the flange 108. In one example, two duct sections can be bonded together by bolting together each flange 108 via the bolts holes 168. Prior to bolting together each flange, a sealant may be placed on each flange. After joining the sections, the space between the two separate sections (e.g., field joint) may be filled with insulation and then surrounded by one or more draw bands that completely enclose the field joint between the two grease duct sections.

[0061] It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages.