SYSTEM AND METHOD FOR SHAPING A DUCT SECTION

FIELD OF THE INVENTION

[0001] The present invention relates to a method for shaping ducts, such as for example mining ducts.

BACKGROUND OF THE INVENTION

[0002] Ducts are conduits or passages used in heating, ventilation, and air conditioning to deliver and remove air. The needed airflows include, for example, supply air, return air, and exhaust air. Ducts commonly also deliver ventilation air as part of the supply air.

[0003] Referring to Figure 1 , there is shown a known method for shaping duct sections 10 that are installed for example in underground mining. The duct sections 10 are typically made of pliable, semi-rigid plastic material or the like, as known by persons skilled in the art. Each duct section 10 is normally shipped in a folded configuration for ease of transportation. At the installation site, the duct sections 10 are unpacked from a transport crate and laid on the floor in a flattened configuration. Each duct section 10 may be about 3 feet to 9 feet (0.91 to 2.74 meters) wide when in the flattened configuration and about 8 to 10 feet (2.44 to 3.05 meters) in length. Each duct section 10 is then manually reshaped to a desired shape, such as oval or round. In a round shaped configuration, the duct section 10 may have a diameter of about 2 feet to 7 feet (0.61 to 2.13 meters). Arrows 12 illustrate manual pressure that is applied by installers to un-flatten and shape each duct section 10. Thereafter, two metallic rings 14 are inserted around the ends of each duct section 10 as illustrated by arrows 16 so as to maintain the round configuration of the duct section 10. Finally, the duct sections 10 are lifted as illustrated by arrow 18 and inserted into position with one another, while the ducts sections 10 are adjusted to follow a drift curvature.

[0004] The main drawbacks of the above prior art method are that it requires several workers to manually shape the duct sections and it is time consuming operation. In addition, workers have to exsert relatively strong forces to shape the duct sections 10 and not everyone may have the required strength to do so.

[0005] There is therefore a need for an improved system and method to shape duct sections that would require a lower number of workers and not as much physical strength from an installer.

SUMMARY OF THE INVENTION

[0006] According to the present invention, there is provided a system for shaping a duct section, the duct section configured to expand from a flattened configuration to an expanded configuration, the system comprising: an inflatable enclosure insertable within the duct section while being in the flattened configuration, the inflatable enclosure defining an opening for inflating the inflatable enclosure; and a blower for inflating the inflatable enclosure through the opening from a deflated configuration to an inflated configuration; wherein when the inflatable enclosure is inserted within the duct section, the blower inflates the inflatable enclosure through the opening from the deflated configuration to the inflated configuration, whereby the duct section expands from the flattened configuration to the expanded configuration as the inflatable enclosure pushes against the duct section from within.

[0007] In embodiments, the system further comprises a cap for closing the opening and sealing the inflatable enclosure.

[0008] In embodiments, the inflatable enclosure may comprise plastic material, aramid material (such as Kevlar™), fabric material or combinations thereof.

[0009] In embodiments, there is also provided a method for shaping a duct section, the duct section being configured to expand from a flattened configuration to an expanded configuration, the method comprising: inserting an inflatable enclosure within the duct section while being in the flattened configuration, the inflatable enclosure defining an opening for inflating the inflatable enclosure; and inflating the inflatable enclosure with a blower through the opening from a deflated configuration to an inflated configuration, whereby the duct section expands from the flattened configuration to the expanded configuration as the inflatable enclosure pushes against the duct section from within.

[0010] In embodiments, the method comprises closing the opening with a cap or valve for sealing the inflatable enclosure.

[0011] In embodiments, the method comprises installing a ring around an end of the duct section to maintain the expanded configuration of the duct section.

[0012] In embodiments, the method comprises deflating the inflatable enclosure after the duct section has reached the expanded configuration.

[0013] Other objects, advantages and features of the present invention will become more apparent upon reading of the following non-restrictive description of specific embodiments thereof, given by way of example only with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 is schematic diagram illustrating a known method for shaping a duct section.

[0015] Figure 2 is a schematic diagram of an inflatable enclosure in a deflated configuration, according to a preferred embodiment of the present invention. [0016] Figure 3 is a schematic diagram of an inflatable enclosure in an inflated configuration and a blower, according to a preferred embodiment of the present invention.

[0017] Figure 4 is a perspective top view of an inflatable enclosure in a deflated configuration, according to a preferred embodiment of the present invention.

[0018] Figure 5 is a perspective view of two duct sections in a flattened configuration and an inflatable enclosure in a deflated configuration, according to a preferred embodiment of the present invention.

[0019] Figure 6 is a perspective view of an inflatable enclosure in a deflated configuration being inserted within a duct section in a flatted configuration, according to a preferred embodiment of the present invention.

[0020] Figure 7 is a perspective view of an inflatable enclosure in an inflated configuration being inserted within a duct section in an expanded configuration, according to a preferred embodiment of the present invention.

[0021] Figure 8 is a perspective view of an inflatable enclosure in an inflated configuration being inserted within a duct section in an expanded configuration, according to a preferred embodiment of the present invention.

[0022] Figure 9 is a perspective view of an inflatable enclosure in an inflated configuration, according to a preferred embodiment of the present invention.

[0023] Figure 10 is a schematic view of different sizes of shaped ducts, according to preferred embodiments of the present invention.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0024] The present invention is illustrated in further details by the following non-limiting examples.

[0025] Referring to Figure 2, there is shown a schematic diagram of an inflatable enclosure 20 in a deflated configuration. The inflatable enclosure 20 defines an opening 22 for inflating the inflatable enclosure 20. The inflatable enclosure 20 may be made of any suitable material strong enough to allow for expansion and exsert a sufficient force against a duct section 10 to be shaped from within. A cap 24 or valve 24’ may be used to seal the opening 22. The inflatable enclosure 20 may be provided with more than one opening 22, with each opening having a corresponding cap or valve to seal the opening.

[0026] The inflatable enclosure 20 may be made of any suitable plastic material, and/or aramid material (such as Kevlar ^TM ), and/or fabric material or combinations thereof. The materials of the inflatable enclosure 20 must be strong enough to push the inner walls of the duct section 10. [0027] Referring now to Figure 3, in addition to figure 2, there is shown a schematic diagram of the inflatable enclosure 20 in an inflated configuration. The inflatable enclosure may be inflatable by means of a blower 26 through the opening 22.

[0028] Referring to Figures 4 and 5, in addition to Figure 3, there is shown another example of the inflatable enclosure 20 in a deflated configuration. The inflatable enclosure 20 includes a handle 25 that may be used to pull it. There are also shown to two duct sections 10 in a flattened configuration. A hose 28 is shown connected at one end thereof to the opening 22 of the inflatable enclosure 20. The hose 28 is connected at its other end to the blower 26. The blower 26 is configured to inject pressurized air or gas into the inflatable enclosure 20 at a pressure level sufficient so as to push and shape from within the inner walls of the duct section 10.

[0029] Referring now to Figure 6, there is shown the inflatable enclosure 20 in a deflated configuration that has been inserted within the duct section 10 in a flatted configuration. The handle 25 may be provided with a rope 27 to assist in pulling the deflated enclosure 20 from the duct section 10.

[0030] Referring now to Figure 7, in addition to Figure 6, there is shown the inflatable enclosure 20 in an inflated configuration inserted within a duct section 10 in an expanded configuration. Therefore, when the inflatable enclosure 20 is connected to the blower 26 (shown in Figure 3), the duct section 10 expands from the flattened configuration to the expanded configuration as the inflatable enclosure 20 pushes against the duct section 10 from within.

[0031] Referring to Figures 8 and 9, in addition to Figures 1 to 6, there is shown another embodiment of the inflatable enclosure 20 in an inflated configuration inserted within a duct section 10 in an expanded configuration. The inflatable enclosure 20 includes the handle 25. The inflatable enclosure 20 includes a first tubular opening 30 provided with a cap or valve 31 and a second tubular opening 32 provided with another cap or valve 33. A metallic ring 14 is shown adjacent to the duct section 10 for subsequent installation as discussed above.

[0032] Figure 10 illustrates different sizes of expanded configurations of a circular duct 10 and an oval duct 10’. The circular duct 10 may be shaped from 24, 30, 42, 48, 54, 60 and 72 inches in diameter. The oval duct 10’ may be shaped from 40.34, 48.27, 56.60, 62.32, and 68.28 inches in diameter. Persons skilled in the art will understand that other sizes may be achieved.

[0033] Although the inflatable enclosure 20 is shown in an inflated configuration being round as seen from the end of the duct section 10, persons skilled in the art will understand that other shaped may be achieved, such as oval, or any suitable shape. [0034] The inflatable enclosure 20 may be provided with air valves, such as the one commercialized by Defender™. The inflatable enclosure 20 may also include a Turn Tite™ pressure test plug. Any suitable air blower 26 for inflating the inflatable enclosure 20 with compressed air or other gases may be used such as the ones commercialized by Makita™ or Milwaukee Tool™ or Dewait™.

[0035] In embodiments, a method for shaping the duct section 10 includes a first step of inserting the inflatable enclosure 20 within the duct section 10 while being in the flattened configuration. The method includes a second step of inflating the inflatable enclosure 20 with a blower 24 through the opening 22 from a deflated configuration to an inflated configuration, whereby the duct section 10 expands from the flattened configuration to the expanded configuration as the inflatable enclosure 20 pushes against the duct section 10 from within.

[0036] Once the duct section 10 has reached its expanded configuration, such as rounded or oval, metallic rings 14 (shown in Figure 1) may be installed at the ends thereof, as is know by persons skilled in the art to maintain the expanded configuration of the duct section 10. Thereafter, the inflatable enclosure 20 may be deflated via one of its openings or valves. The deflated enclosure 20 is then removed from within of the duct section 10. The duct section 10 may thus be installed.

[0037] The main advantages of the present system and method is that these require less workers to shape the duct sections 10 and in less time than the known method of the prior art. In addition, present system and method do not require that the workers exsert manual and physical force to shape the duct sections 10.

[0038] The scope of the claims should not be limited by the preferred embodiments set forth in the examples but should be given the broadest interpretation consistent with the description as a whole.

[0039] DEFINITIONS

[0040] The use of the terms "a" and "an" and "the" and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context.

[0041] The terms "comprising", "having", "including", and "containing" are to be construed as open-ended terms (i.e., meaning "including, but not limited to") unless otherwise noted.

[0042] Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All subsets of values within the ranges are also incorporated into the specification as if they were individually recited herein.

[0043] All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context.

[0044] The use of any and all examples, or exemplary language (e.g., "such as") provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed.

[0045] No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0046] Herein, the term "about" has its ordinary meaning. In embodiments, it may mean plus or minus 10% or plus or minus 5% of the numerical value qualified.

[0047] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.