Abstract:
Embodiments of the present invention relate to arcuate saddles with partial ribs typically used to anchor and suspend insulated or non-insulated pipes. Partial ribs on the lower face of the saddle inhibit the saddle from sliding relative to the hanger when engaged and provide strengthening force to the saddle. 
     Objects, features and advantages of the present invention shall become apparent from the detailed drawings and descriptions provided herein.

Description:
[0001]    This application claims the benefit of U.S. provisional application Ser. No. 60/891,098 filed on Feb. 22, 2007, which is hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    Aspects of the present invention relate generally to saddles for anchoring and supporting insulated and uninsulated pipes. Saddles are typically used in building construction to anchor and support pipes to suspend the pipes from the structure of the building. Saddles typically spread the force of a hanger across a portion of the pipe to minimize the force applied to a particular spot. Arcuate flat saddles and saddles with 180° arcuate ribs ( FIG. 1 ) are well known in the art. An improved saddle is desired. 
       SUMMARY 
       [0003]    Embodiments of the present invention relate to arcuate saddles with partial ribs typically used to anchor and suspend insulated or non-insulated pipes. Partial ribs on the lower face of the saddle inhibit the saddle from sliding relative to the hanger when engaged and provide strengthening force to the saddle. 
         [0004]    In certain embodiments of the present invention, an arcuate saddle comprises a saddle which has a length and a width formed into an arc defined by a radius. The arcuate saddle further includes an exterior face on the saddle and a pair of partial ribs with closed ends protruding from the exterior face. 
         [0005]    Objects, features and advantages of the present invention shall become apparent from the detailed drawings and descriptions provided herein. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a perspective view of a prior art saddle with 180° arcuate ribs. 
           [0007]      FIG. 2  is an example of a hanger assembly usable to suspend saddles according to embodiments of the present invention. 
           [0008]      FIG. 3  illustrates a hanger assembly and saddle supporting a pipe according to a preferred embodiment of the present invention. 
           [0009]      FIG. 4  is lower perspective view of an arcuate saddle according to one embodiment of the present invention. 
           [0010]      FIG. 5  is a lower view of the saddle of  FIG. 4 . 
           [0011]      FIG. 6  is side view of the saddle of  FIG. 4 . 
           [0012]      FIG. 7  is a downward or interior view of the saddle of  FIG. 4 . 
           [0013]      FIG. 8  is a die usable to make arcuate saddles according to embodiments of the present invention. 
           [0014]      FIG. 9  is an enlarged partial view of the die of  FIG. 8 . 
           [0015]      FIG. 10  is a cross-sectional view of a die assembly usable to make arcuate saddles according to embodiments of the present invention. 
           [0016]      FIG. 11  is a cross-sectional view of a die assembly usable to make arcuate saddles according to embodiments of the present invention. 
           [0017]      FIG. 12  is a framed view of a roll bending machine to make arcuate saddles according to embodiments of the present invention. 
           [0018]      FIG. 13  is a framed view of an optional sensor assembly on the machine of  FIG. 12 . 
           [0019]      FIG. 14  is a perspective view of the die assembly of  FIG. 10  with a sensor. 
       
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0020]    For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations, modifications, and further applications of the principles of the invention being contemplated as would normally occur to one skilled in the art to which the invention relates. 
         [0021]    Embodiments of the present invention relate to arcuate saddles with partial ribs typically used to anchor and suspend insulated or non-insulated pipes. As illustrated in  FIGS. 2 and 3 , in a typical assembly  10  a hanger assembly  20  wraps around a pipe or insulated pipe  15  with a saddle  30  situated between the lower portion of the hanger and the pipe. According to an embodiment of the present invention, partial ribs  50  on the lower face of the saddle inhibit the saddle from sliding relative to the hanger when engaged and provide strengthening force to the saddle. 
         [0022]    When putting together assembly  10 , an installer takes saddle  30  and slides it through lower bracket  24  of hanger  20  either independently or with the introduction of pipe  15  into the hanger. Partial ribs  50  are generally on the lower face or side of saddle  30  and do not extend upward to the vertical sides. The vertical sides of saddle  30  have a width in a close tolerance with the interior of hanger lower bracket  24  to transfer suspension force from the pipe to the hanger once in place. Typically the ribs in a prior art saddle, such as 180° ribs shown in  FIG. 1 , have a higher profile and larger radius than the interior of hanger particularly on the sides, making sliding introduction of the prior art saddles into the hanger difficult. Omitting rib portions from the sides of the saddle allows the saddle to be introduced with a slight lifting above the lower hanger portion to clear the lower ribs, but without concern for side rib portions which might otherwise require lifting or twisting of the saddle relative to the hanger sides. 
         [0023]    Partial ribs  50  according to certain preferred embodiments are considered closed at their ends, for example with the ends tapered into the face of the saddle. Closing the ends and omitting rib portions from the sides of the saddle allows the lower hanger portion to engage the sides of the saddle and pipe  15  in a flush or no-gap arrangement between the saddle side and hanger and between the saddle side and pipe and preferably with a friction fit once engaged. This flush arrangement substantially closes and seals the hanger to the saddle side and the saddle to the pipe and prevents the accumulation or retention of moisture or debris in the rib, such as water, dust, mold, or bacteria, which could accumulate in an open ended rib, such as in the 180 degree arcuate ribbed saddle of  FIG. 1 . 
         [0024]    Hanger  20 , for example the clevis hanger illustrated in detail in  FIG. 2 , typically includes an upper portion or bracket  22  which can be suspended from a building structure, a lower bracket  24  for receiving and engaging the saddle and pipe and optionally includes a pivot  26  between the upper and lower brackets to allow some relative movement of the hanger portions, if necessary due to vibration, expansion or contraction. Alternately, the hanger can be one piece or a strap which suspends a pipe and saddle. 
         [0025]      FIGS. 4-7  illustrate saddle  30  according to one preferred embodiment. Saddle  30  is formed typically from a metal sheet  32  pressed or rolled into approximately a 180° arcuate bend about a radius R, forming a length L and a width W. Saddle  30  includes two ends  33  and  34  at opposing ends of the saddle length. Ends  33  and  34  are optionally slightly outwardly flared  35  at each end to facilitate introduction of the pipe into the saddle and to minimize any abutment of sharp edges against the pipe or insulation. The exterior face of saddle  30  includes a generally lower portion or lower face  38  and opposing vertical sides  39 . “Vertical” and “lower” references herein refer to arcuate or curved portions of the saddle which may include generally vertical or horizontal tangents and are not intended to imply planar or flat portions. 
         [0026]    The outer diameter or width W of saddle  30  is preferably sized to closely correspond to the inner diameter or width W C  of the lower bracket  24  of hanger  20 . As examples, pipe sizes may range from 0.5 to 24 inches. More typical saddle sizes have outer diameters of 1.5 to 12 inches, optionally available in half-inch increments, although other outer diameter sizes can be made as desired. Example lengths are 8 or 12 inches 
         [0027]    An interior channel  42  extends through the interior  44  of saddle  30  along channel axis C. In use, the interior diameter of channel  42  is sized to receive and engage an outer diameter of a corresponding pipe or insulated pipe. 
         [0028]    Partial ribs  50  are defined on the lower face  38  of saddle  30 . Ribs  50  typically have an arcuate bend corresponding in shape to the arcuate curve of lower face  38 . Partial ribs  50  are generally transverse to the length L of saddle  30  and parallel to the width W. Ribs  50  preferably extend a sufficient height and width to inhibit saddle  30  from moving relative to the lower bracket  24  of hanger  20  once installed. Ribs  50  are preferably primarily oriented on lower face  38  and do not substantially extend to side portions  39 . In certain preferred embodiments, the arcuate bend of ribs  50  is approximately 60° or less. 
         [0029]    Ribs  50  each include a central peak section  52  and opposing slanted or curved sides extending from face  38  to peak  52 . Peak section  52  may be sharp, blunted or rounded. Ends  56  of the ribs may be sharply defined, but preferably are tapered into saddle  30  at each end to form a closed end. Ribs  50  could be mounted to lower face  38  with an attachment process, but preferably are formed into the metal. 
         [0030]    In one method of manufacture, a piece or “blank” of metal sheet either to be bent or pre-bent into a saddle is placed into a stamping machine which receives the piece. The stamping machine compresses the sheet between mating portions. During the compression, one piece of the press includes protruding partial ribs which stamp corresponding rib sections into the saddle. Optionally, the sheet is bent into an arcuate shape in the same step. 
         [0031]    In an alternate method of manufacture, partially ribbed saddles can be made using a roll bending process using, for example, an Acrotech Model 1618 roll bending machine. A die  130  usable in a roll bending machine  400  ( FIG. 12 ) is illustrated in  FIGS. 8 and 9 . 
         [0032]    Die  130  includes opposing ends  131  which are engaged and driven by the roll bending machine. A central portion of the die has a length L D  corresponding to the length of the saddle piece to be formed. The central portion has opposing ends  133  and  134  along length L D  to form corresponding ends in the saddle. Optionally, ends  133  and  134  are flared  135  on the die to impart a flare to the end portions of the saddle. 
         [0033]    In the embodiment of  FIGS. 8 &amp; 9 , die  130  is a solid cylinder which can be mounted at opposing ends to a roll bending machine to be driven. In an alternate embodiment shown in  FIG. 10 , die  230  is a two piece die with an outer sleeve  235  surrounding an inner cylinder  240 . Inner cylinder  240  has opposing ends which are mountable to a roll bending machine. The outer diameter of inner cylinder  240  preferably forms a close fit with the inner diameter of outer sleeve  235  such that rotation of the inner cylinder by the machine transmits a corresponding rotation to outer sleeve  235 . 
         [0034]    In a still further embodiment illustrated in  FIG. 11 , die  330  includes an outer sleeve  335  with an outer and inner diameter and an inner roller  340 . Inner roller includes a mandrel shaft  344  with opposing ends mountable to a be driven by roll bending machine. Two bearing rollers  348  are mounted to shaft  344  and engage channels  337  defined adjacent opposing ends on the inner diameter of outer sleeve  335 . As inner roller  340  is turned, it causes sleeve  335  to rotate at a rate proportional to the ratio between the channel diameter C D  and the diameter R D  of bearing rollers  348 . 
         [0035]    The die diameter is preferably sized to the diameter of a desired arcuate saddle, with different sizes usable for different sized saddles. By way of example only, a solid die, such as die  130 , can be used for saddles up to approximately four (4) inches in diameter. A two-piece die with an inner cylinder, such as die  230 , may be preferred for saddles from approximately four (4) inches in diameter to five (5) inches in diameter. A two-piece die with an inner shaft driving a sleeve, such as die  330 , may be preferred for saddles with a diameter of approximately five (5) inches or larger. 
         [0036]    The outer surface of the die defines partial ribs which press corresponding rib portions into the saddle during the roll bending process. For example, in dies  130 ,  230  and  330  the partial ribs are  150 ,  250  and  350  respectively. The ribs of die  130  are described in detail, with ribs  250  and  350  being similar yet appropriately sized to the corresponding die diameter. As shown in detail in  FIG. 9 , ribs  150  preferably include a transverse length with a peak  152  and opposing side portions  154 . The ends of the partial ribs  156  are preferably tapered into the curve of die  130 . Partial ribs  150  are preferably formed on a face of die  130  to correspond in placement to a lower portion of saddle  30 , with blank portions on opposing sides of the ribs on die  130  to form corresponding non-ribbed side portions in the saddle. 
         [0037]    A portion of an example roll bending machine  400  is shown in  FIG. 12 . To form a piece of sheet metal into an arcuate saddle, a blank piece is preferably fed between two rollers, one of which is die  130 , with the length placed to correspond to the central portion of the die. Preferably the die is arranged and timed to rotate and form the partial ribs in the lower face of the arcuate saddle while bending each saddle. One method of arranging such timing is to start the die at a specific rotational point relative to the introduction of each blank sheet to form a saddle. An alternate method uses an automated or timed feeding mechanism to introduce blanks only at specified points relative to the rotation of die  130  while the die is in continuous rotation. 
         [0038]    In certain embodiments, for example those shown in  FIGS. 13 and 14 , a roll bending machine incorporates a sensor to consistently start the die at a specific rotational point relative to the introduction of each blank sheet to form a saddle. The sensor can be mechanical, such as a cam, wheel or lever, or electrical such as a light sensor or an electrical circuit. 
         [0039]    In one embodiment, illustrated with die  130  in  FIG. 13 , a cam  170  is mounted to an end of die  130 . A lever  175  is eccentrically pivotally mounted to cam  170  offset from the die axis, and extends through a bracket  177  towards a two-position switch  180 . Lever  175  is pulled and pushed through bracket  177  during rotation of die  130 . In use, a saddle blank is arranged at a feed point into the roll bending die with lever  175  at its extended position relative to switch  180 . The switch is then activated, for example by pushing handle  184  inward to push switch  180  to engage the roll bending machine to feed and bend the saddle blank into an arcuate saddle with rib portions while simultaneously pulling and then pushing lever  175  during the rotation cycle. When the die has made one complete revolution, lever  175  returns to its extended position and pushes switch  180  outward to disengage the rolling process. Preferably, at the end stopping point of the die rotation the protruding ribs on the die are positioned to be synchronized with the desired rib placement for when the next saddle blank is fed into the machine. 
         [0040]    In an alternate embodiment, illustrated on die  230  in  FIG. 14  yet usable in various die sizes, a registry point is defined on the die, and a sensor disengages the rolling process when the registry point reaches a desired position. In the example illustrated, die  230  includes a hole or depression  250  adjacent an end, for example on the exterior face or shoulder of sleeve or on an end face of the sleeve. A sensor  450  is arranged to detect when the hole or depression reaches a desired registry point. In one example, sensor  450  is a spring-biased wheel  452  mounted on a stalk  455  extending from machine  400 . In use, the process is engaged with a manual switch or sensor when a blank is in place or with an automated feed process. The wheel  452  is pushed outward by the die face during rotation of the die, and is biased to move slightly inward to engage the hole or depression when aligned with the registry point. The slight inward movement of wheel  452  preferably disengages the rolling process. Preferably, at the end stopping point of the die rotation the protruding ribs on the die are positioned to be synchronized with the desired rib placement for when the next saddle blank is fed into the machine. 
         [0041]    While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.