The present disclosure relates generally to air ducts for HVAC systems (Heating Ventilating and Air Conditioning systems) and more specifically to inflatable air ducts with low height-to-width ratios.
Ductwork is often used for conveying conditioned air (e.g., heated, cooled, filtered, etc.) to or from a room or other areas within a building. Conventional ducts are made of sheet metal and have a substantially fixed internal volume regardless of whether the duct is conveying supply air to a room or return air from the room.
Sheet metal ducts are often installed above suspended ceilings for convenience; however, in warehouses, manufacturing plants and other industrial installations, it can be more practical and less expensive to install the ductwork underneath the ceiling. Sheet metal ducts underneath a ceiling, however, can create problems in those installation sites where prevention of air-borne contamination of inventory or other items is critical.
For instance, temperature variations in the building or temperature differentials between the ducts and the air being conveyed can create condensation on the interior or exterior of the ducts. The presence of condensed moisture on the interior of the duct may form mold or bacteria that the duct then passes onto the room or other areas being supplied with the conditioned air. In the case of exposed ducts, condensation on the exterior of the duct can drip onto the inventory or personnel below. The consequences of the dripping can range anywhere from a minor irritation to a dangerously slippery floor or complete destruction of products underneath the duct (particularly in food-processing facilities).
Further, metal ducts with localized discharge registers have been known to create uncomfortable drafts and unbalanced localized heating or cooling within the building. In many food-processing facilities where the target temperature is 42 degrees Fahrenheit, a cold draft can be especially uncomfortable and perhaps unhealthy.
Many of the above problems associated with metal ducts are overcome by the use of inflatable fabric ducts, such as DUCTSOX from DuctSox Corporation of Peosta and Dubuque, Iowa. Inflatable ducts typically have a pliable fabric wall (sometimes porous) that inflates to a generally cylindrical shape by the pressure of the air being conveyed within the duct. Fabric ducts seem to inhibit the formation of condensation on its exterior wall, possibly due to the fabric having a lower thermal conductivity than that of metal ducts. In addition, fabric porosity and/or additional holes distributed along the length of the fabric duct broadly and evenly disperse the air into the room being conditioned or ventilated. The even distribution of airflow also effectively ventilates the walls of the duct itself, thereby further inhibiting the formation of mold and bacteria.
Example air duct systems disclosed herein comprise an inflatable air duct that is extra wide to contain multiple side-by-side airways, including at least one intermediate airway between two other airways. The air duct systems are particularly suited for conveying air in HVAC systems (Heating Ventilating and Air Conditioning systems). A novel arrangement of internal restraints, external hangers and an overhead support system increase (e.g., maximize) the vertical clearance underneath the duct, regardless of whether the duct is inflated or deflated. In some examples, the overhead support system is a rectangular array of both lengthwise and crosswise supports. In some examples, the external hangers are of different vertical lengths. Some examples include an inflatable manifold. Some example ducts provide an airflow path that is non-linear (e.g., varies in elevation and/or in lateral direction).
Referring to
In some examples, the pliable wall 20 of the duct 12 comprises a top sheet 36, a bottom sheet 38, a first side sheet 40 and a second side sheet 42. The pliable wall 20 is what divides an interior 44 from an exterior 46 of the duct 12. A combination of the sheets 36, 38, 40, 42, in some examples, is one continuous sheet of material. In some examples, the pliable wall 20 includes one or more seams. In some examples, the pliable wall 20 has a first seam 48 and a second seam 50 along the top sheet 36, whereby a relatively large sheet section 52 encompasses the bottom sheet 38, the side sheets 40, 42, and parts of the top sheet 36; and a much smaller sheet section 54 extends partially across the top sheet 36 between the seams 48, 50.
Example materials of the pliable wall 20 include, but are not limited to, vinyl, polyester sheeting, and polyester fabric. Some example materials are perforated, porous, impervious to gas, or are combinations thereof (e.g., some porous areas and some areas impervious to gas). Some example materials are impregnated or coated with a sealant, such as acrylic or polyurethane. Some example materials are uncoated. Some example materials are fire or heat resistant.
In some examples, as shown in
To help maintain the shape of the duct 12, some examples of the internal restraints 28, as shown in
The restraints 28 help determine the shape of the duct 12 in the duct's inflated and deflated states. In the inflated state, as shown in
In the illustrated example, the overhead support system 32 comprises at least one or a plurality of lengthwise supports 94 and at least one or a plurality of crosswise supports 96. The lengthwise supports 94 are elongate in the longitudinal direction 22, and the crosswise supports 96 are elongate in the lateral direction 62. The phrase, “crosswise support being elongate in a lateral direction perpendicular to the longitudinal direction,” means that opposite ends of the crosswise support are spaced farther apart in the lateral direction than in the longitudinal direction, so the crosswise support does not necessarily lie perpendicular to the longitudinal direction, but rather the crosswise support is closer to lying perpendicular to the longitudinal direction than parallel to it.
Examples of the lengthwise supports 94 include, but are not limited to, a rail, a beam, a bar, a track, a pipe, a tube, an extrusion, a ceiling of a building, a building rafter, a building truss, a ceiling joist, and a taut cable. In some examples, the lengthwise support 94 is an aluminum extruded track, and any suitable mounting hardware 98 connects the lengthwise support 94 to the ceiling 34 (e.g., the ceiling of a building, underground mine, tunnel, etc.). Examples of the crosswise supports 96 include, but are not limited to, a rod, a beam, a rail, a bar, a track, a pipe, a tube, and an extrusion. In some examples, the crosswise support 96 is a fiberglass rod.
In some examples, the lengthwise supports 94 have an extruded lateral cross-sectional profile that makes them stiffer than the crosswise supports 96. In some examples, the lengthwise supports 94 are cables that are more flexible than the crosswise supports 96; however, cable-style lengthwise supports held in tension can provide the desired support to carry the weight of the duct 12. In some examples, the lengthwise supports 94 carry more suspended weight than do the crosswise supports 96.
The hangers 30, which suspend the duct 12 from the overhead support 32, are vertically elongate members. Examples of the hangers 30 include, but are not limited to, rope (e.g., a transition hanger 30a), straps (e.g., transition hangers 30b and side hanger 30c), ribbons, cables, wires, chains, elastic chords (of limited elastic length), fabric strips, rigid rods, and rigid bars.
To increase (e.g., maximize) the vertical clearance underneath the duct 12 in both its inflated and deflated states, the hangers 30 are at certain locations and are of different vertical lengths. In some examples, each of the transition hangers 30b, for instance, is sewn or otherwise attached to a point 100 on an inflated valley 102 of the inflated duct 12, just above the transition area 88. This allows an inflated peak 104 of the inflated duct 12 to be higher than the hanger-to-duct point of attachment 100. In some examples, an upper end 106 of the hanger 30b attaches to a connector 108 on the lengthwise support 94. In some such examples, when the duct 12 is in its deflated state, as shown in
To provide the duct 12 with vertical support across the duct's width, the hangers 30a, 30c connect certain points of the duct 12 to the crosswise support 96. Each transition hanger 30a, for instance, is connected to a point (e.g., the point 100) directly above each restraint 28, thereby supporting the duct 12 at the transition areas 88, 90, 92. In some examples, the transition hangers 30a are ropes sewn to the duct 12 and loop over the crosswise support 96. In the illustrated example, the transition hangers 30a are appreciably shorter than the transition hangers 30b so that when the duct 12 is inflated, portions of the top sheet 36 bulge above the crosswise support 96. More specifically, the top sheet 36 includes a movable section 114 having selectively a sagging position (
To reduce (e g, minimize) sagging of the side sheets 40, 42 when the duct 12 is deflated, in some examples, each side hanger 30c loops over the crosswise support 96 and is sewn or otherwise attached to the duct 12 at a point 116 proximate the first side sheet 40 or the second side sheet 42. At this location, the inflated peak 104 is laterally situated between the side hanger 30c and the transition hanger 30a. The side hanger 30c is appreciably longer than the transition hanger 30a because the point 116 is lower than the point 100 while both the hangers 30a, 30c connect to the same crosswise support 96. The illustrated example maintains the duct's upper points of attachment (e.g., the points 100, 116) at a substantially fixed height so that the restraints 28 can suspend the bottom sheet 38 at a generally constant elevation regardless of whether the duct 12 is inflated or deflated. Although the crosswise supports 96 of the illustrated example might flex, the support system 32 overall provides the duct 12 with significant vertical stability.
The air passageway of the first duct section 118 defines a first longitudinal centerline 122, and the air passageway of the second duct section 120 defines a second longitudinal centerline 124. The longitudinal centerlines 122, 124 are displaced out of collinear alignment, either angularly and/or curved.
Referring to
The air passageway of the first duct section 128 defines a first longitudinal centerline 132, and the air passageway of the second duct section 130 defines a second longitudinal centerline 134. The longitudinal centerlines 132, 134 are displaced out of collinear alignment, either angularly and/or curved.
Although certain example methods, apparatus and articles of manufacture have been described herein, the scope of the coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.
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Entry |
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Prihoda, “Fabric Ducting & Diffusers”, www.prihoda.com/us, Jan. 2014, 32 pages. |
Number | Date | Country | |
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20150192318 A1 | Jul 2015 | US |