The present invention relates to ductwork components for air handling systems such as residential, commercial, or industrial heating, ventilating, and air conditioning (HVAC) systems. More particularly, it relates to an integrally formed, foam-based air handling system ductwork component(s) exhibiting superior handling and performance properties.
Residential, commercial, and industrial air handling systems include various ductwork components used to direct heated, cooled, and/or filtered air from a source to one or more rooms. More particularly, the air handling system can include a heating system (e.g., furnace, heat pump, electrical heat, etc.), cooling system (e.g., air conditioner), and/or a filtering system. Regardless of the manner in which air is treated, ductwork components direct the treated air (typically via fan(s) or blower(s)) to the room(s) of interest. The ductwork components can include one or more of a plenum (e.g., hot air plenum, cold air straight plenum, cold air plenum with furnace take-off), hot air take-offs, ducts, pipes (e.g., straight or bent), boots, wall stacks, registers (e.g., wall or floor registers), tees, reducers, etc. (hereinafter referred to as “ductwork components”). These ductwork components are traditionally formed of metal; more particular, galvanized stainless steel or sheet metal. While well accepted, stainless steel or sheet metal ductwork components are characterized by a number of potential drawbacks.
For example, metal ductwork components are not energy efficient. Heat transfer across a thickness of the component readily occurs, especially during periods of inactivity. Similarly, difficulties are often encountered when joining two separate ductwork components (e.g. a duct to a plenum; a register to a boot; etc.) due to variation in size. Along these same lines, it is virtually impossible to achieve an airtight seal between two joined ductwork components; instead, an additional sealing material (e.g. duct tape) must be employed to ensure an airtight junction. Due to the extra time required to apply this auxiliary sealant, installers operating under tight deadlines may be forced to forego their use. This failure, in turn, may lead to the introduction of unwanted molds, dust, and bacteria into the air handling system ductwork. Further, the sharp corners associated with many metal ductwork components are dangerous and may cause injuries during installation. Also, though galvanized stainless steel is quite robust, deterioration or rupturing will inevitably occur over time due in large part to corrosion.
Efforts have been made to address at least one of the above-identified concerns. Namely, a separate layer of insulation is often wrapped around pipe ductwork components to minimize undesirable heat transfer. The separately formed insulation layer(s) is expensive and entails handling difficulties and additional installation time. Alternatively, U.S. Pat. No. 3,352,326 to Gustafson describes a prefabricated duct for an air conditioning system consisting of inner and outer metal tubes maintaining an intermediate fiberglass insulation material. Unfortunately, the prefabricated ducts are not adapted to retrofit existing systems. Similarly, ductboard is available that incorporates an intermediate insulation layer as described, for example, in U.S. Pat. No. 5,918,644. Regardless of exact construction, ductboard is provided in a sheet or blank form, and then bent to form a duct. As such, ductboard has minimal structural strength and is limited to above ground, separately reinforced air duct applications. A further drawback common to each of the above described ductwork insulation techniques is that they are limited to only pipe and duct components. Likely due to the greatly increased costs associated with these techniques, no efforts have been made to provide other ductwork components (e.g., plenums, boots, etc.) with an insulation layer.
Substantial efforts have been expended into improving the design and performance of the “major” air handling system components such as furnaces and air conditioners. However, the ductwork components are essentially unchanged, relying solely upon traditional metal fabrication. Any improvements to this metal design could revolutionize the residential, commercial, and industrial air handling system industry. Unfortunately, previous efforts have not produced commercially viable results. Therefore, a need exists for air handling system ductwork components that are integrally formed to include a layer of insulation and that can be produced on a cost effective basis.
An air handling system 10 incorporating ductwork components (referenced generally at 12) in accordance with the present invention is shown in
With the above in mind, an exemplary component 12 in accordance with the present invention is an air duct 14 (referenced generally in
As used throughout this specification, a “foam” or “foam material” is a lightweight cellular material resulting from the introduction of gas bubbles into a reacting polymer. With this definition in mind, the interior foam layer 16 is preferably a molded, hardened or rigid foam having a relatively high density, such as that normally associated with molded polyethylene foam as described below. These preferred foam characteristics render the interior foam layer 16 to have a high compression modulus or support factor sufficient for the duct 14 (or other ductwork component as described below) to rigidly maintain its shape over long periods of time (at least ten years) when subjected to forces normally encountered in a residential, commercial, or industrial air handling system ductwork application (e.g., the duct 14 may be buried under ground, hung from a ceiling, etc.).
In light of the above-described characteristics associated with the foam interior layer 16 (e.g., molded, rigid foam), the outer layer 18 primarily serves as protective coating or skin that maintains an integrity of the duct's 14 exterior during handling and installation. In particular, the foam interior layer 16 can be somewhat friable; the outer layer 18 limits possible crumbling or flaking of the foam interior layer 16 in the event the duct 14 accidentally contacts another hard object. Further, as described below, the outer layer 18 provides a smooth, aesthetically pleasing exterior surface for the duct 14 and/or desired color. However, the outer layer 18 need not overtly support a structural rigidity of the inner foam layer 16, and thus is a preferably thin, hardened plastic such as polyethylene. In particular, the outer layer 18 preferably has a thickness of less than 0.25 inch (6.35 mm), more preferably less than 0.125 inch (3.175 mm), most preferably less than 0.0625 inch (1.587 mm). Further, although the interior layer 16 and the outer layer 18 are depicted in
In one preferred embodiment, the duct 14 is formed by a rotational molding (or roto-molding) technique. In general terms, rotational molding is a process in which parts are formed with heat and rotation. A mold that has been tooled to a desired shape (e.g., a duct) is placed in a rotational molding machine that provides loading, heating, and cooling areas. A pre-measured plastic resin is loaded into the mold in the machine loading area. Subsequently, the mold and resin are subjected to a source of heat to melt the plastic resin under controlled conditions. In particular, the mold is rotated bi-axially (vertically and horizontally) such that the melting resin sticks to the hot mold and evenly coats every surface thereof. The mold continues to rotate during a cooling cycle so that the resulting part retains an even wall thickness. Rotational molding has conventionally been employed to produce various plastic-only parts such as furniture and toys. With the present invention, however, it has surprisingly been found that an acceptable combination foam interior layer and plastic outer layer ductwork component can be provided via rotational molding.
In one preferred embodiment, the material used to rotational mold the duct 14 includes a plastic resin and a foaming agent. The selected plastic resin and foaming agent constituents are selected to generate the interior layer 16 as a rigid, closed cell foam and the outer layer 18 as a relatively thin, encapsulating plastic skin. In this regard, the preferred plastic resin is polyethylene, more preferably linear low-density polyethylene (LLDPE). Alternatively, other polyethylene formulations, such as high-density polyethylene (HDPE), low-density polyethylene (LDPE), etc., are acceptable. Even further, other plastic resins, such as other polyolefins, ethylene-vinyl acetate, polyvinyl chloride, polyester, nylon, polycarbonate, polyurethane, etc., can be employed. In one preferred embodiment, the plastic resin is LLDPE-based, available under the trade designation “LL8460” from ExxonMobile of Toronto, Ontario, Canada. Alternative plastic resin compounds are available, for example, from A. Schulman of Akron, Ohio, under the trade designation “LBAXL0360”.
The selected foaming agent in combination with the selected plastic resin generates the foam interior layer 16 during rotational molding. With this in mind, one preferred foaming agent is available under the trade name “Celogen” from UniRoyal Chemical Company, of Hartford, Conn., as an activated azodicarbonamide. When heated during the molding process, the foaming agent generates a gas that is trapped inside the molten plastic and causes it to foam. The material then has porous walls that are stiffer but lighter in weight than a solid wall of the same strength.
In a preferred embodiment, the molding compound consists of a ratio of plastic resin and foaming agent as approximately 2:3 (i.e., 40% plastic resin and 60% foaming agent). This one preferred ratio has surprisingly been found to result in a molded, highly rigid yet lightweight foam interior layer in combination with a hardened, smooth, aesthetically pleasing outer layer or skin. In this regard, the foaming agent is preferably added shortly after the heating/rotation cycling has begun. With this one preferred technique, the plastic resin melts and forms the thin outer layer 18, with the subsequently added foaming agent causing foaming to occur, with this foamed layer/material being integrally formed or bonded to the outer skin layer. Alternatively, a dry blend of the plastic resin and foaming agent can be combined and placed into the mold prior to heating/rotation, resulting in an integral skin foam. Even further, assembly techniques other than rotational molding can be employed, such as laminating the outer layer 18 to a pre-formed foam interior layer 16, injection molding the layers 16, 18, etc.
By preferably forming the interior layer 16 as a closed cell foam, a consistent interior surface is provided for directing airflow. That is to say, the interior layer 16 can be “exposed” to airflow (i.e., define the interior surface of the duct) without concern for airborne particles intimately interacting with individual cells of the foam interior layer 16 and/or air “leaking” through the foam interior layer 16. This is in direct contrast to previous rotational molded parts in unrelated fields that sandwich an insulative material between inner and outer plastic layers. However, in an alternative embodiment, the duct 14 further includes a molded inner layer 19, that in combination with the outer layer 18, encapsulates the foam interior layer 16 as shown in
Formulation of the molding compound can further include other additives that enhance certain characteristics of the resulting ductwork component. For example, the plastic and foaming agent components are preferably selected to provide the foam interior layer 16 with an elevated R value for enhanced insulative effects and thus be highly useful for extreme temperature applications (e.g., attic or crawl space). For example, in one preferred embodiment, the duct 14 can have an R value of eighteen or greater. Conversely, for air handling applications where an elevated R value is not a critical factor, the selected materials and/or resulting wall thickness can result in a lower R value. Additionally, a flame retardant additive can be employed.
Also, a desired colorant or pigment additive can be used to produce a desired exterior color for the duct 14. Any heat stable and unreactive colorants known and available for use with the selected plastic resin (and foaming agent with the preferred rotational molding technique) can be employed. Illustrative examples of useful colorants include carbon black, quinaeridone red, anthraquinone, and perinone dyes to name but a few. The resulting ductwork component (such as the duct 14) can thus be virtually any color, such as black, red, yellow, brown, etc. Other optional additives include fillers, tackifying agents, dispersing agents, UV stabilizers, and/or antioxidants.
Returning to
Others of the ductwork components 12 are described in greater detail below. As a general statement, each of these components 12 is preferably identical in construction to the duct 14 described above, though different in shape and size. More particularly, each of the ductwork components 12 described below are provided as integrally formed tubular bodies consisting of a rigid, interior foam layer and an outer non-metal, preferably plastic, layer. In this regard, each of the ductwork components 12 described below are preferably rotational molded parts, having a closed cell interior foam layer that defines an interior surface of the particular component.
With additional reference to
In addition to the hot air plenum 30, the ductwork component 12 of the present invention can include a cold air plenum/take-off 40 or a cold air straight plenum 42 as shown in greater detail in
Additional ductwork components include straight pipes, an exemplary one of which is shown at 60 at
Additionally, though not specifically shown in
Yet another ductwork component 12 in accordance with the present invention is a curved duct take-off component 80 as shown in greater detail in
Yet another ductwork component 12 in accordance with the present invention is a boot, such as a 90° floor boot 100 shown in greater detail in
Yet another ductwork component 12 in accordance with the present invention is a wall stack 120, shown in greater detail in
Returning to
Ductwork components in accordance with the present invention were produced. In particular, 8″×16″ five-foot ducts, 16″×14″ reducers, and 6″ 90° take-offs ductwork components were rotational molded at Custom Roto-Mold, Inc. of Benson, Minn., using a customized rotational molding machine manufactured by Ferry Industries, Inc., of Stow, Ohio. For each of the ductwork components, an appropriately sized and shaped mold was formed and mounted within the rotational molding machine. A LLDPE resin available under the trade designation “LL8460” from ExxonMobile of Toronto, Ontario, Canada, was loaded into the mold, and the rotational molding machine operated (e.g., heated and bi-axially rotated) for approximately 10 minutes, resulting in a thin layer of LLDPE being formed along the mold wall. Cycling of the rotational molding machine was then stopped, and a foaming agent, available under the trade name “Celogen” from UniRoyal Chemical Company, of Hartford, Conn., was dispensed into the mold. The ratio of foaming agent:LLDPE was 3:2. Operation of the rotational molding machine was then resumed for approximately 40 minutes, including a cooling cycle. The resulting ductwork component was removed from the mold.
Each of the ducts, reducers and 90° take-offs produced above included a rigid, closed cell foam interior layer. Each ductwork component was properly sized for use in an air handling system, and exhibited minimal heat transfer. All exterior surfaces were highly smoothed, and readily resisted scratching or other forms of deterioration.
As should be evident from the above, the present invention is in no way limited to circular pipes. Instead, virtually any ductwork component is available with the present invention. In a preferred embodiment, all major ductwork of a particular air handling system is comprised of components provided in accordance with the present invention. During assembly, the precisely defined male and female ends of the respective components are easily and directly joined to one another and produce an airtight fitting without the requirement of a separate sealing material. Of course, some installation layouts may require modification of one or more of the ductwork components 12, such as, for example, creating a hole through one of the ducts 14 to facilitate fluid coupling to another component, such as a take-off. Alternatively, however, one or more of the ductwork components can be of a conventional type (i.e., sheet metal), with the corresponding ductwork component in accordance with the present invention being easily joined thereto (e.g., a floor boot in accordance with the present invention being assembled to a metal straight pipe). Even further, ductwork components in accordance with the present invention can be used to retrofit an existing system. For example, an existing air handling system can include a number of different ductwork components, each formed of conventional sheet metal or galvanized steel. In the event that a particular ductwork component requires replacement (e.g., a floor boot has been damaged or otherwise deteriorated), the existing, metal boot is simply removed and replaced with the integrally molded, foam insulated boot in accordance with the present invention.
In light of the above, the present invention provides a marked improvement over previous designs. Ductwork components in accordance with the present invention represent a significant improvement over conventional, metal designs. There is no need for additional insulation to be applied during an installation procedure, as the foam interior layer is highly energy efficient. Further, the preferred rotational molding technique renders the resulting ductwork component smooth, with rounded corners. The ductwork components are non-toxic, non-allergenic, and water resistant. Further, the precise dimensional characteristic of each component are such that a sealed relationship is achieved upon joining two components, eliminating the need for duct tape or other sealant materials.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes can be made in form and detail without departing from the spirit and scope of the present invention.
This application is a continuation of U.S. patent application Ser. No. 10/252,032, filed Sep. 19, 2002, which claims priority to provisional patent application Ser. No. 60/324,160 filed on Sep. 20, 2001, the teachings of both of which are incorporated herein by reference.
Number | Date | Country | |
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60324160 | Sep 2001 | US |
Number | Date | Country | |
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Parent | 10252032 | Sep 2002 | US |
Child | 11930984 | Oct 2007 | US |