Abstract:
What is presented is heating, ventilation, and air conditioning (HVAC) ductwork. The HVAC ductwork comprises a strip of material, which is divided into a plurality of circumferential segments by a plurality of living hinges. The living hinges allow the HVAC ductwork to unfold for transportation and storage purposes. The strip of material has both a first locking mechanism and a second locking mechanism that are adapted to interlock with each other at an interlocking site, to create the assembled HVAC ductwork.

Description:
This application takes priority from U.S. provisional application No. 61/649,696 filed May 21, 2012, which is incorporated herein by reference. 
    
    
     BACKGROUND 
     Heating, ventilation, and air conditioning (HVAC) is a general term encompassing environmental control of a building. HVAC systems typically connect heating and cooling units through a variety of ductwork and accessories such as conduits, duct collars, outlets, vents, etc. Of these types of ductwork, the duct collars and conduits are typically cylindrical in shape and bulky, and take up large volumes of space while still having a relatively light weight. This shape makes the shipping and marketing of these HVAC conduits and duct collars to be more expensive than necessary. Thus, there is a demand for solutions towards reducing the volume of HVAC conduits and duct collars when shipping to reduce overall shipping and marketing costs. What is presented is foldable HVAC ductwork, such as a conduit and duct collar, which decreases shipping costs as well as provides packaging and marketing opportunities for the HVAC industry. 
     Foldable devices within a variety of fields, similar to HVAC field, have been created in the past. However, these devices are made to solve the problem of connecting and disconnecting two parts of a conduit together. None of these devices unfold out sufficiently to address the problems associated with shipping bulky HVAC conduits and ductwork. Thus, what is presented herein is a non-obvious solution to a long felt problem. 
     SUMMARY 
     What is presented is foldable heating, ventilation, and air conditioning (HVAC) ductwork. The HVAC ductwork comprises a strip of material, which is divided into a plurality of circumferential segments by a plurality of living hinges. The living hinges allow the HVAC ductwork to unfold for transportation and storage purposes. The strip of material has both a first locking mechanism and a second locking mechanism located on it. The first locking mechanism and the second locking mechanism are both adapted to interlock with each other at an interlocking site to create assembled HVAC ductwork. 
     The HVAC ductwork could have a circular cross-section when it is properly assembled. The strip of material could be made from a molded polymer. The HVAC ductwork could have a finishing seal that is applied to the interlocking site, to facilitate an air tight seal in the properly assembled HVAC ductwork. 
     The HVAC ductwork could have a flange extending from at least one of its circumferential segments so that when assembled the HVAC ductwork forms into an HVAC duct collar. The previously assembled HVAC duct collar could also include a damper that is installed within it. 
     What is also presented is an HVAC duct collar with a circular cross-section that connects to an HVAC conduit. The HVAC duct collar comprises a polymer molded strip of material, which is divided into a plurality of circumferential segments by a plurality of living hinges, which has a first locking mechanism and a second locking mechanism. The living hinges allow the HVAC duct collar to unfold for transportation and storage purposes. The HVAC duct collar also comprises a flange, which extends laterally from an edge of at least one of the circumferential segments. The first locking mechanism and second locking mechanism are each adapted to interlock with each other at an interlocking site. 
     The HVAC duct collar could comprise a finishing seal that is applied to the interlocking site, which facilitates an air tight seal in the assembled HVAC duct collar. The HVAC duct collar could also comprise a damper that is installed within it. 
     Those skilled in the art will realize that this invention is capable of embodiments that are different from those shown and that details of the devices and methods can be changed in various manners without departing from the scope of this invention. Accordingly, the drawings and descriptions are to be regarded as including such equivalent embodiments as do not depart from the spirit and scope of this invention. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       For a more complete understanding and appreciation of this invention, and its many advantages, reference will be made to the following detailed description taken in conjunction with the accompanying drawings. 
         FIG. 1  is a perspective view of the assembled HVAC duct collar; 
         FIG. 2  is a top view of the assembled HVAC duct collar of  FIG. 1 ; 
         FIG. 3  is a perspective view of the unfolded HVAC duct collar of  FIG. 1 ; 
         FIG. 4  is a top view of the unfolded HVAC duct collar of  FIG. 1 ; 
         FIG. 5  is a side view of the unfolded HVAC duct collar of  FIG. 1 ; 
         FIG. 6  is an exploded view of the assembled HVAC duct collar with an installed damper and gasket; 
         FIG. 7  is a perspective view of another embodiment of an assembled HVAC conduit; 
         FIG. 8  is a top view of the unfolded HVAC conduit of  FIG. 7 ; 
         FIG. 9A  is an embodiment of the locking mechanisms of the HVAC ductwork; 
         FIG. 9B  is another embodiment of the locking mechanisms of the HVAC ductwork; 
         FIG. 9C  is another embodiment of the locking mechanisms of the HVAC ductwork; and 
         FIG. 9D  is another embodiment of the locking mechanisms of the HVAC ductwork. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to the drawings, some of the reference numerals are used to designate the same or corresponding parts through several of the embodiments and figures shown and described. Corresponding parts are denoted in different embodiments with the addition of lowercase letters. Variations of corresponding parts in form or function that are depicted in the figures are described. It will be understood that variations in the embodiments can generally be interchanged without deviating from the invention. 
     As shown in  FIGS. 1 and 2 , an assembled foldable HVAC duct work is an HVAC duct collar  10  that is a tube around the central axis  14  with a circular cross-section  12 , a length  16 , and a width  18 . As best shown in  FIGS. 3-5 , the unfolded HVAC duct collar  10  is also shaped to allow HVAC ductwork, such as conduits, to connect to it. The HVAC duct collar  10  comprises a polymer molded strip of material  20  that is made through an injection molding machine. The strip of material  20  is divided up into a plurality of circumferential segments  22  having equal lengths by a plurality of living hinges  24 . The HVAC duct collar  10  comprises at least two living hinges  24 , so there will be a minimum of three circumferential segments  22  on the HVAC duct collar  10 . It will be understood that the strip of material  20  may be made from a material other than a molded polymer, such as, but not limited to, an elastomer or metallic material. One having ordinary skill in the art will also see that the assembled foldable HVAC duct collar  10  may have a cross-section that is some shape other than circular, including, but not limited to, octagonal or square. 
     The living hinges  24  flexibly bend back and forth to allow the HVAC duct collar  10  to unfold out. Each living hinge  24  is a thin hinge (flexure bearing) that allows motion through its bending and is made from the same molded polymer material as the strip of material  20 , including the two circumferential segments  22  to which the living hinge  24  creates and connects. To create a living hinge  20  a straight line is cut along the body of the strip of material  20 , and the flanges  26  (discussed below), that is just deep enough to allow the circumferential segments  22  on both sides of the living hinge  24  to bend. When each of the living hinges  24  are folded properly, they assemble the entire HVAC duct collar  10  into its circular shape. When unfolded, the living hinges  24  turn the HVAC duct collar  10  into a relatively flat strip with a linear orientation, so that the unfolded HVAC duct collar  10  uses less space and can be stacked with other unfolded HVAC duct collars  10 . Since they are simple to make, these living hinges  24  are cost effective to create while manufacturing the respective HVAC duct collar  10 . 
     Each of the circumferential segments  22  is a sectioned-off portion of the strip of material  20  that forms the walls of the HVAC duct collar  10  when assembled. A laterally extending flange  26  also protrudes outward and away from the central axis  14  of the assembled HVAC duct collar  10 . The flange  26  allows at least one joining mechanism (not shown) to be inserted through its body so as to ensure the assembled HVAC duct collar  10  will stay in a stationary position when successfully installed into a wall, ceiling, or other surface. Each flange  26  is located at or near (within approximately an inch of) the edge of the circumferential segment  22  that it extends from laterally. Positioning the flange  26  at this location allows for the use of a cover (not shown), or other similar additional element, over the HVAC duct collar  10  in certain instances when the HVAC duct collar  10  and all associated ductwork is installed. One of ordinary skill in the art will see that each flange  26  could be located anywhere along the body of its respective circumferential segment  22  while still adequately performing its function. It will be understood that the flange  26  is an essential element in creating the assembled HVAC duct collar  10 . Without a single flange  26 , the assembled HVAC duct collar  10  is simply an HVAC conduit. 
     Referring to  FIGS. 1 through 5 , a locking mechanism set, having both a first locking mechanism  32  and a second locking mechanism  34 , is found at both ends of the length of the strip of material  20 . Both the first locking mechanism  32  and second locking mechanism  34  are adapted to interlock with each other to create an interlocking site  36 , which is the equivalent of a seam between the interlocked ends of the length of the strip of material  20 . In this embodiment the first locking mechanism  32  is a tab and the second locking mechanism  34  is an adapted hole to which the first locking mechanism  32  mates. Typically, the strip of material  20  incorporates two sets of locking mechanisms  32  and  34  to properly assemble and secure the HVAC duct collar into its tube shape, but it should be understood that the strip of material  20  can incorporate more than two sets. One having ordinary skill in the art will also see that a finishing seal (not shown) may also be applied to the interlocking site  36 . This finishing seal ensures that the interlocking site  32  is air tight, which may be needed in certain instances after installation. The finishing seal could be an adhesive material fixedly applied over and covering the interlocking site  36 , but the finishing seal is not limited solely to this embodiment. 
     A variety of devices may be centrally installed within the assembled HVAC duct collar  10 . As shown in  FIG. 6 , for example, a damper  28  having a corresponding circular cross-section to the HVAC duct collar  10  is installed. The damper  28  functions to regulate the airflow passing out of the HVAC duct collar  10 , from the connected HVAC ductwork. The damper  28  also adds structure to the assembled HVAC duct collar  10  that assists in maintaining the tube shape of the HVAC duct collar  10 . Other devices could be installed within the assembled HVAC duct collar  10 , such as, but not limited to, vents, louvers, fans, etc. Each of these other devices, in addition to performing their respective function, will further assist the HVAC duct collar  10  in maintaining the tube shape around the central axis. A gasket  30  may also be placed on the flanges  26 , which is a mechanical seal that fills the space between the flanges  26  and the a wall, ceiling, or other surface (not shown), to prevent leakage from or into the HVAC duct collar  10  when properly installed on the wall, ceiling, or other surface. 
     As shown in  FIGS. 7 and 8 , another embodiment an assembled foldable HVAC ductwork is an HVAC conduit  10   a  to a duct that is a tube around the central axis  14   a  and has a circular cross-section  12   a . In this embodiment, the assembled HVAC conduit  10   a  has a length  16   a  that is considerably longer than its width  18   a . In fact, the only difference between this embodiment of the assembled HVAC conduit  10   a  and the previous embodiment, as discussed above, is the length  16   a  of the assembled HVAC conduit  10   a  and the absence of a flange. The HVAC conduit can be made into a variety of lengths and can be formed into a variety of diameters of assembled tubing. 
     As shown in  FIG. 9A , a locking mechanism set, having both a first locking mechanism  32   b  and a second locking mechanism  34   b , is found at both ends of the length of the strip of material  20   b . Both the first locking mechanism  32   b  and second locking mechanism  34   b  are adapted to interlock with each other to create an interlocking site  36   b , which is the equivalent of a seam between the interlocked ends of the length of the strip of material  20   b . In this embodiment the first locking mechanism  32   b  is a tab and the second locking mechanism  34   b  is an adapted hole to which the first locking mechanism  32   b  mates. Typically, the strip of material  20   b  incorporates two sets of locking mechanisms  32   b  and  34   b  to properly assemble and secure the HVAC duct collar into its tube shape, but it should be understood that the strip of material  20   b  can incorporate more than two sets. One having ordinary skill in the art will also see that a finishing seal (not shown) may also be applied to the interlocking site  36   b . This finishing seal ensures that the interlocking site  32   b  is air tight, which may be needed in certain instances after installation. The finishing seal could be an adhesive material fixedly applied over and covering the interlocking site  36   b , but the finishing seal is not limited solely to this embodiment. 
     As shown in  FIG. 9B , a locking mechanism set, having both a first locking mechanism  32   c  and a second locking mechanism  34   c , is found at both ends of the length of the strip of material  20   c . Both the first locking mechanism  32   c  and second locking mechanism  34   c  are adapted to interlock with each other to create an interlocking site  36   c , which is the equivalent of a seam between the interlocked ends of the length of the strip of material  20   c . In this embodiment the first locking mechanism  32   c  and second locking mechanism  34   c  together complete a buckle. The first locking mechanism  32   c  is the male part that mates with and locks into the second locking mechanism  34   c , which is the female part. Typically, the strip of material  20   c  incorporates two sets of locking mechanisms  32   c  and  34   c  to properly assemble and secure the HVAC duct collar into its tube shape, but it should be understood that the strip of material  20   c  can incorporate more than two sets. One having ordinary skill in the art will also see that a finishing seal (not shown) may also be applied to the interlocking site  36   c . This finishing seal ensures that the interlocking site  32   c  is air tight, which may be needed in certain instances after installation. The finishing seal could be an adhesive material fixedly applied over and covering the interlocking site  36   c , but the finishing seal is not limited solely to this embodiment. 
     As shown in  FIG. 9C , a locking mechanism set, having both a first locking mechanism  32   d  and a second locking mechanism  34   d , is found at both ends of the length of the strip of material  20   d . Both the first locking mechanism  32   d  and second locking mechanism  34   d  are adapted to interlock with each other to create an interlocking site  36   d , which is the equivalent of a seam between the interlocked ends of the length of the strip of material  20   d . In this embodiment the first locking mechanism  32   d  is a hook and second locking mechanism  34   d  is the loop in which the first locking mechanism  32   d  hooks into. Typically, the strip of material  20   d  incorporates two sets of locking mechanisms  32   d  and  34   d  to properly assemble and secure the HVAC duct collar into its tube shape, but it should be understood that the strip of material  20   d  can incorporate more than two sets. One having ordinary skill in the art will also see that a finishing seal (not shown) may also be applied to the interlocking site  36   d . This finishing seal ensures that the interlocking site  32   d  is air tight, which may be needed in certain instances after installation. The finishing seal could be an adhesive material fixedly applied over and covering the interlocking site  36   d , but the finishing seal is not limited solely to this embodiment. 
     As shown in  FIG. 9D , a locking mechanism set, having both a first locking mechanism  32   e  and a second locking mechanism  34   e , is found at both ends of the length of the strip of material  20   e . Both the first locking mechanism  32   e  and second locking mechanism  34   e  are adapted to interlock with each other to create an interlocking site  36   e , which is the equivalent of a seam between the interlocked ends of the length of the strip of material  20   e . In this embodiment the first locking mechanism  32   e  and second locking mechanism  32   e  form a snap fit latch. The first locking mechanism  32   e  is the barbed male part of the latch that that mates with and locks into the second locking mechanism  34   c , which is the female part. With this embodiment, once the first locking mechanism  32   e  has mated with and locked into the second locking mechanism  34   e , the two mechanisms are permanently interlocked and their interlocking cannot be undone. Typically, the strip of material  20   e  incorporates two sets of locking mechanisms  32   e  and  34   e  to properly assemble and secure the HVAC duct collar into its tube shape, but it should be understood that the strip of material  20   e  can incorporate more than two sets. One having ordinary skill in the art will also see that a finishing seal (not shown) may also be applied to the interlocking site  36   e . This finishing seal ensures that the interlocking site  32   e  is air tight, which may be needed in certain instances after installation. The finishing seal could be an adhesive material fixedly applied over and covering the interlocking site  36   e , but the finishing seal is not limited solely to this embodiment. 
     It should be understood that any form of locking mechanism that functions to secure the assembled HVAC ductwork into its tube shape may be implemented into the HVAC ductwork. Other embodiments of locking mechanisms (not shown) may include, but are not limited to, zippers, teeth, pins, adhesives, welding, or any combination thereof. 
     This invention has been described with reference to several preferred embodiments. Many modifications and alterations will occur to others upon reading and understanding the preceding specification. It is intended that the invention be construed as including all such alterations and modifications in so far as they come within the scope of the appended claims or the equivalents of these claims.