Patent Publication Number: US-2022235964-A1

Title: Ducting system for hvac application

Description:
TECHNICAL FIELD 
     The presently disclosed subject matter generally relates to a component for use in heating ventilation and air conditioning (HVAC) applications. Particularly, the present subject matter relates to an insulated ducting system for use in HVAC applications. 
     BACKGROUND 
     HVAC applications typically employ ducting for purposes of routing air from one location to another. For example, in an air conditioning or heating system, the heated or cooled air may need to be transported from an air handler positioned on an exterior of a building, or another unconditioned space, to multiple locations within the building. This requires that the ducting be insulated from any exterior temperatures. Ever increasing stringent norms such as the federal and state guidelines of various jurisdictions mandate that an R-value for the duct work be based off the temperature variations recommended by the climate zone map of the Department of Energy. 
     Many ducting systems have been developed in the past to overcome the drawback of applying excessive manual effort that is typically required during installation of an insulated ducting system for a HVAC application. One traditionally implemented approach for installing a duct is by oversizing the duct beforehand so that an inner perimeter of the oversized duct is rendered large enough to accommodate an insulating liner therein. One of the many drawbacks with this traditionally known approach is that inner edges of the duct would then also need to have fasteners that are installed with a spot welder, or screws, while the insulating liner, typically, mineral wool, may be glued and pressed over the fasteners to secure the insulating liner to the inner perimeter of the duct. This process of fastening and gluing the insulating liner entails a significantly increased amount of time and effort by an experienced technician for making and/or assembling the duct prior to installation and use in the HVAC application. 
     Besides, with the foregoing method of installing the duct, the insulation would remain subject to moisture and temperature changes within the air stream of the duct when in operation. Owing to this, the insulation liner and/or the glue holding the insulation liner to the inner perimeter of the duct can come undone upon prolonged exposure to the moisture and temperature changes that are also concomitantly encountered with changes in weather. At the least, the insulation liner could likely be subject to mold as well when exposed to moisture. Moreover, the insulation liner may also prevent the technicians or workers from performing one or more service routines such as cleaning an interior of the duct as the cleaning process itself may inadvertently deteriorate, or even remove, the insulation from the inner perimeter of the duct. 
     Another approach to ducting is to install the insulation layer, in this case—a grade of exterior rated foam such as Johns Manville AP™ Foil-Faced Polyiso Foam Sheathing that is suitable for exterior use, on exterior surfaces of the duct. The insulation layer may be glued, or screwed, to the exterior surface of the duct and wrapped using an adhesive coated aluminum cladding. However, this method requires a skilled technician to first cut individual pieces of the foam to form a board to each side of the duct, then wrap the boards with the cladding, and smooth the edges of the wrapped, or clad, foam i.e., the insulation layer. This approach may pose challenges in that air gaps, if any, between the cut insulation layer and the cladding could lead to a ripping, tearing, deterioration or even failure of one or both of the cladding and the insulation layer. Moreover, although a skilled technician may be used for implementing this approach to ducting i.e., for installing the insulation layer on the exterior surface of the duct, in most cases, a final fit and finish of the assembled duct may still be less than optimum and therefore, may have poor aesthetics. Moreover, performing duct work using this method does not protect the duct work from impact as deterioration can be caused by simple loads, for example, foot traffic i.e., by one or more persons stepping on or over the duct, or by setting of tools on the exterior surfaces of the duct during routine maintenance. Moreover, a warranty period for the AP™ Foil-Faced Polyiso Foam Sheathing, if installed properly, is prescribed to be ten years which is less than one-third the typical life expectancy of the duct itself thus requiring frequent replacement and/or repair to continue maintaining optimum thermal efficiency for the installation. 
     Many approaches to ducting have been implemented in the past to overcome one drawback or another. However, these previously known approaches may be regarded by some as being a chore while for others, they may be considered tedious, or at least cumbersome, activities to undertake. Also, an amount of strength and durability in the construction of and, consequently, a reliability of the duct assembly in operation may also be less than optimal with the use of these approaches. In fact, duct assemblies obtained with the use of these traditional approaches may be of poor structural integrity as well and, in most cases, would consequently be incapable of providing support to technicians, or other components in the vicinity of the duct, for example, these other components may need to be supported by the duct, or when these technicians would need access to those other components and may need to walk over the duct. 
     Keeping the foregoing discussion in view, it would, therefore, be prudent to implement a ducting system that is simple to manufacture, or assemble, yet easy to install in a HVAC application. Further, in view of the aforementioned drawbacks, there also exists a need for a ducting system that is robust in construction and that which, owing to its construction, can easily support other structures, or technicians, thereon and still obviates the need for extraneous manual effort that was typically incurred in the manufacture and installation of previously known duct assemblies. 
     SUMMARY 
     To overcome the above-mentioned limitations and problems, the present disclosure provides a ducting system for an exterior rated insulated duct work for any HVAC application that can be manufactured fairly easily and quickly without the need for extraneous manual effort compared to traditionally known duct assemblies. Also, the present disclosure provides a ducting system that offers pleasing aesthetics while also being robust in construction. 
     An embodiment of the present disclosure provides a ducting system for a HVAC application. The ducting system includes a duct assembly having an inner duct member and an outer duct member disposed around the inner duct member such that the outer and inner duct members together define a pre-determined amount of space therebetween. The ducting system also includes a bonding and insulation composite that is disposed in the pre-determined amount of space between the inner and outer duct members to insulate the inner and outer duct members from each other yet adhesively bond with each of the inner and outer duct members for imparting structural rigidity to the duct assembly. 
     According to an aspect of the present disclosure, the ducting system further includes a pair of adjacently located duct assemblies that are connected to each other by butting corresponding ones of inner and outer duct members from the pair of adjacently located duct assemblies with an interfacing gasket therebetween. 
     According to another aspect of the present disclosure, the outer duct member of each duct assembly includes an end that is configured to define thereon, a transverse duct flange (TDF) such that, in use, the TDF from one duct assembly is connected to a proximally located, and mutually opposing, TDF of another duct assembly from the pair of adjacently located duct assemblies. 
     According to another aspect of the present disclosure, the outer duct member is concentrically located with respect to the inner duct member. According to a further aspect of the present disclosure, the ducting system may include a plurality of jigs disposed within the pre-determined amount of space between the inner and outer duct members. Each jig from the plurality of jigs is configured to connect the outer duct member and the inner duct member such that the pre-determined amount of space between the inner and outer duct members is uniform across a cross-sectional area of the duct assembly. 
     According to another aspect of the present disclosure, a width of the space is based on a desired amount of R-value between the inner and outer duct members. 
     According to another aspect of the present disclosure, the bonding and insulation composite is deposited within the pre-determined amount of space as flowable media, and the flowable media expands and hardens into a non-flowable state over a pre-determined period of time prior to installation of the duct assembly within the HVAC application. 
     According to another aspect of the present disclosure, the bonding and insulation composite is formed using a mixture having an R-value of not less than 13 if the width of the space between the outer and inner duct members is 2 inches. 
     According to another aspect of the present disclosure, the bonding and insulation composite is formed using a closed-cell Polyurethane and resin mixture. 
     According to another aspect of the present disclosure, the bonding and insulation composite is a thermal and fluid impermeable insulation that is configured to hermetically seal the space between the inner and outer duct members. 
     Another embodiment of the present disclosure provides a method for forming a ducting system for a HVAC application. The method includes forming a duct assembly by providing an inner duct member. Further, the method also includes positioning an outer duct member around, and co-axially with, the inner duct member such that the outer and inner duct members together define a pre-determined amount of space therebetween. Furthermore, the method also includes providing a bonding and insulation composite in the pre-determined amount of space between the inner and outer duct members such that the bonding and insulation composite insulates the inner and outer duct members from each other yet adhesively bonds with each of the inner and outer duct members for imparting structural rigidity to the duct assembly. 
     According to an aspect of the present disclosure, the method further includes providing a pair of adjacently located duct assemblies and connecting the pair of adjacently located duct assemblies to each other by butting corresponding ones of the inner and outer duct members from the pair of adjacently located duct assemblies with an interfacing gasket therebetween. 
     According to an aspect of the present disclosure, the method further includes forming a transverse duct flange (TDF) on an end of the outer duct member of each duct assembly, and connecting the TDF from one duct assembly to a proximally located, and mutually opposing, TDF of another duct assembly from the pair of adjacently located duct assemblies. 
     According to an aspect of the present disclosure, the method further includes locating the outer duct member concentrically with respect to the inner duct member. According to a further aspect of the present disclosure, the method further includes providing a plurality of jigs within the pre-determined amount of space to connect the outer duct member and the inner duct member such that the pre-determined amount of space between the inner and outer duct members is uniform across a cross-sectional area of the duct assembly. 
     According to another aspect of the present disclosure, a width of the space is based on a desired amount of R-value between the inner and outer duct members. 
     According to another aspect of the present disclosure, providing the bonding and insulation composite within the pre-determined amount of space includes depositing the bonding and insulation composite within the pre-determined amount of space as flowable media and allowing the flowable media to expand and harden into a non-flowable state over a pre-determined period of time prior to installation of the duct assembly within the ducting system. 
     According to another aspect of the present disclosure, the method further includes using a mixture to form the bonding and insulation composite such that the bonding and insulation composite has an R-value of not less than 13 if the width of the space between the outer and inner duct members is 2 inches. 
     According to another aspect of the present disclosure, the bonding and insulation composite is formed using a closed-cell Polyurethane and resin mixture. 
     According to another aspect of the present disclosure, the bonding and insulation composite is a thermal and fluid impermeable insulation that is configured to hermetically seal the space between the inner and outer duct members. 
     Other and further aspects and features of the disclosure will be evident from reading the following detailed description of the embodiments, which are intended to illustrate, not limit, the present disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The illustrated embodiments of the disclosed subject matter will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices and processes that are consistent with the disclosed subject matter as claimed herein. 
         FIG. 1  is a front perspective view of a ducting system for a HVAC application, in accordance with an embodiment of the present disclosure; 
         FIG. 2  is a side perspective view of a ducting system, in accordance with an embodiment of the present disclosure; 
         FIG. 3  is a flowchart of a method for forming the ducting system, in accordance with an embodiment of the present disclosure; 
         FIG. 4A  is a flowchart of a sub-routine pursuant to the method of  FIG. 3  in accordance with an exemplary embodiment of the present disclosure while  FIG. 4B  is a flowchart pertaining to a step of the sub-routine of  FIG. 4A ; and 
         FIGS. 5A-5I  are diagrammatic representations for illustrating a process of manufacturing the ducting system pursuant to the method of  FIG. 3 . 
     
    
    
     DETAILED DESCRIPTION 
     The following detailed description is made with reference to the figures. Exemplary embodiments are described to illustrate the disclosure, not to limit its scope, which is defined by the claims. Those of ordinary skill in the art will recognize a number of equivalent variations in the description that follows. 
     Reference throughout this specification to “a embodiment,” “an embodiment,” or “one embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosed subject matter. Thus, appearances of the phrases “in an embodiment” or “in one embodiment” in various places throughout this specification are not necessarily referring to the same embodiment. 
     Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided, to provide a thorough understanding of embodiments of the disclosed subject matter. One skilled in the relevant art will recognize, however, that the disclosed subject matter can be practiced without one or more of the specific details, or with other structures, components, and materials as substitution or replacement to the structures, components, materials disclosed herein. In other instances, one or more structures, components, and materials disclosed herein may altogether be omitted, and equivalent structures, components, materials may be used in lieu thereof. Also, in the present disclosure, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the disclosed subject matter. 
       FIG. 1  shows a front perspective view of a ducting system  100  for a HVAC application, in accordance with an embodiment of the present disclosure. As shown, the ducting system  100  includes a duct assembly  102  having an inner duct member  104  and an outer duct member  106  disposed around the inner duct member  104 . 
     In embodiments herein, each of the inner and outer duct members  104 ,  106  may be made from similar or dissimilar metallic materials such as galvanized steel, stainless steel, or aluminum, but is not limited thereto. It is hereby envisioned that a specific choice of materials used to form respective ones of the inner and outer duct members  104 ,  106  may be based on various factors including costs per unit length and environmental factors present at a location, for example, a site at which the installation is to be made. Although some factors have been disclosed herein, a number of factors is not limited thereto, and persons skilled in the art will acknowledge that other factors may be taken into consideration and such factors determining a choice of material/s for forming the inner and outer duct members  104 ,  106  may not be construed as being limiting of this disclosure in any way. In embodiments herein, the outer and inner duct members  106 ,  104  together define a pre-determined amount of space  108  therebetween. In a further embodiment as shown in the view of  FIG. 1 , the outer duct member  106  is concentrically located with respect to the inner duct member  104 . In this embodiment, the ducting system  100  may also include a plurality of jigs  110  that are disposed within the pre-determined amount of space  108  between the inner and outer duct members  104 ,  106 . The jigs  110  are made to keep the inner and outer ducts  104  and  106  aligned and spaced properly. Without the jigs  110 , the polyurethane insulation material may warp or bend one of the sides. The jigs  110  are particularly necessary at the ends where one assembly may meet with another and all the surfaces need to line up properly. 
     Each jig  110  is configured to connect the outer duct member  106  and the inner duct member  104  such that the pre-determined amount of space  108  between the inner and outer duct members  104 ,  106  is uniform across a cross-sectional area of the duct assembly  102 . Moreover, the jigs  110  also help to keep intact a straightness of each of the inner and outer duct members  104 ,  106 , or stated differently, the jigs  110  help to maintain the inner and outer duct members  104 ,  106  rigidly in their respective positions and therefore, maintain not only a straightness of each of the inner and outer duct members  104 ,  106  but also consequently maintain the uniformity of the space between the inner and outer duct members  104 ,  106 . 
     Further, the ducting system  100  includes a bonding and insulation composite  112  that is disposed in the pre-determined amount of space  108  between the inner and outer duct members  104 ,  106  to insulate the inner and outer duct members  104 ,  106  from each other yet adhesively bond with each of the inner and outer duct members  104 ,  106  for imparting structural rigidity to the duct assembly  102 . 
     In an embodiment, a width ‘W’ of the space  108  is based on a desired amount of R-value i.e., the thermal resistance per unit width of the space  108  between the inner and outer duct members  104 ,  106 . 
     In an embodiment, during a manufacture of the ducting system  100 , the bonding and insulation composite  112  would be deposited within the pre-determined amount of space  108  as flowable media, and the flowable media would be allowed to expand and harden into a non-flowable state over a pre-determined period of time prior to installation of the duct assembly  102  within the HVAC application. The pre-determined period of time disclosed herein may range from a few seconds to a few minutes, for example, approximately in the range of 5 seconds to 5 minutes. 
     In an embodiment, the bonding and insulation composite  112  is formed using a mixture having an R-value of not less than 13 if the width ‘W’ of the space  108  between the outer and inner duct members  106 ,  104  is 2 inches. 
     In an embodiment, the bonding and insulation composite  112  is formed using a closed-cell Polyurethane and resin mixture. 
     In an embodiment, the bonding and insulation composite  112  is a thermal and fluid impermeable insulation that is configured to hermetically seal the space  108  between the inner and outer duct members  104 ,  106 . It is hereby envisioned that the thermal and fluid impermeability of the bonding and insulation composite  112  would prevent movement of heat and a fluid, for example, water or air across or through the composite  112  and hence, the bonding and insulation composite  112  would be beneficially rendered in a weather resistant manner. 
       FIG. 2  shows a side perspective view of the ducting system  100  showing a pair of adjacently located duct assemblies  102   a,    102   b  prior to being connected with each other, in accordance with an embodiment of the present disclosure. In the embodiment illustrated in the view of  FIG. 2 , the pair of adjacently located duct assemblies  102   a,    102   b  may be connected to each other by butting corresponding ones of outer duct members  106  from the pair of adjacently located duct assemblies  102   a,    102   b  with an interfacing gasket  214  therebetween. The interfacing gasket  214  may include an elastomer, or another polymer, for example, Butyl rubber, high density polyethylene (HDPE), low density polyethylene (LDPE), or may be formed using other suitable materials commonly known to persons skilled in the art. The interfacing gasket  214  is configured to act, or serve, as a hermetic seal between the pair of adjacently located duct assemblies  102   a,    102   b  upon mutually opposed abutment thereof i.e., by the outer duct members  106  from the pair of adjacently located duct assemblies  102   a,    102   b  as shown by a pair of directional arrows ‘D 1 ’ and ‘D 2 ’ in the view of  FIG. 2 . 
     Further, in this embodiment, the outer duct member  106  of each duct assembly  102  may include an end  216  that is configured to define thereon, a transverse duct flange (TDF)  218  such that, in use, the TDF  218  from one duct assembly  102   a  is connected to a proximally located, and mutually opposing, TDF  218  of another duct assembly  102   b  from the pair of adjacently located duct assemblies  102   a,    102   b.    
     In regards to the foregoing embodiment, only a pair of adjacently located duct assemblies  102   a,    102   b  is depicted as part of the ducting system  100 . However, in other embodiments, more than two duct assemblies  102 , for example, three or more duct assemblies  102  may be positioned, and connected, in a successive manner. These successively positioned duct assemblies  102  may be connected by using a plurality of fastening arrangements (see  FIG. 5H ) that are configured to secure each pair of adjacently located duct assemblies  102   a,    102   b,  . . . and so on from the plurality of successively positioned duct assemblies. In an embodiment, these fastening arrangements may include cleats that designed to clamp onto the pair of proximally located, and mutually opposing, flanges i.e., the TDF&#39;s  218  to secure each duct assembly  102  to a successive, and adjacently located, one of the duct assemblies  102 , for example, duct assemblies,  102   a  and  102   b  that are present in the ducting system  100 . Additionally, proximally located and mutually opposing flanges i.e., TDFs  218  may be secured to each other using one or more bolt and nut arrangements. Alternatively, these fastening arrangements may include rivets or other types of structures that are commonly known to persons skilled in the art and that can be readily implemented for use in securing each pair of adjacently located duct assemblies  102   a,    102   b  . . . and so on that may be present in the plurality of successively positioned duct assemblies  102 . 
       FIG. 3  shows a flowchart of a method  300  showing steps  302 - 304  for forming the ducting system  100 , in accordance with an embodiment of the present disclosure.  FIG. 4A  is a flowchart of a sub-routine  400  pursuant to carrying out the method  300  in accordance with an exemplary embodiment of the present disclosure while  FIG. 4B  is a flowchart of a further sub-routine pertaining to step  408  of the sub-routine  400  from  FIG. 4A . 
     Referring to  FIG. 3 , at step  302 , the method  300  includes forming the duct assembly  102  by providing the inner duct member  104  (see sub-step  302   a ) and positioning the outer duct member  106  around, and co-axially with, the inner duct member  104  such that the outer and inner duct members  106 ,  104  together define the pre-determined amount of space  108  therebetween (see sub-step  302   b ). Referring to  FIG. 4A , the sub-routine  400  includes steps  402 - 406  that are in conformance to step  302  of the method  300 . As shown, at step  402 , the sub-routine  400  of the method  300  includes forming the inner duct member  104 . Further, at step  404 , the sub-routine  400  of the method  300  also includes forming the outer duct member  106  with the TDF  218  (shown in the view of  FIG. 2 ) thereon. Furthermore, at step  406 , the sub-routine  400  of the method  300  includes mounting the inner and outer duct members  104 ,  106  onto the plurality of jigs  110  for proper alignment i.e., to maintain straightness of the inner and outer duct members  104 ,  106  and a uniform width ‘W’ therebetween. 
     Furthermore, at step  304 , the method  300  includes providing the bonding and insulation composite  112  in the pre-determined amount of space  108  between the inner and outer duct members  104 ,  106  such that the bonding and insulation composite  112  insulates the inner and outer duct members  104 ,  106  from each other yet adhesively bonds with each of the inner and outer duct members  104 ,  106  for imparting structural rigidity to the duct assembly  102 , as similarly recited in the step  408  of the sub-routine  400  (see  FIG. 4A ). In the further sub-routine to the step  408  as shown by way of the flowchart in  FIG. 4B , at step  408   a,  the bonding and insulation composite  112  is deposited as a flowable media. Thereafter, with continued reference to  FIG. 4B , at step  408   b  in the further sub-routine to the step  408 , the bonding and insulation composite  112  is allowed to expand and harden into a non-flowable state. 
     Now returning to  FIG. 4A , at step  410 , the excess insulation, upon expansion and hardening of the composite  112 , is trimmed from edges of inner and outer duct members  104 ,  106  so that the insulation and bonding composite  112  is flush with the TDF  218  (see  FIG. 2 ) i.e., for preparing the edges of the inner and outer duct members  104 ,  106  to accomplish a seal by abutment with the interfacing gasket  214 . 
     In an embodiment, the method  300  may also include providing the pair of adjacently located duct assemblies  102   a,    102   b  and connecting the pair of adjacently located duct assemblies  102   a,    102   b  to each other by butting corresponding ones of the outer duct members  106  from the pair of adjacently located duct assemblies  102   a,    102   b  with the interfacing gasket  214  therebetween (refer to  FIG. 2 ). 
     In an embodiment, the method  300  may also include forming the transverse duct flange (TDF)  218  on the end  216  of the outer duct member  106  of each duct assembly  102 , and connecting the TDF  218  from one duct assembly  102  to a proximally located, and mutually opposing, TDF  218  of another duct assembly  102  from the pair of adjacently located duct assemblies  102   a,    102   b  (refer to  FIG. 2 ). 
     In an embodiment, the method  300  may further include locating the outer duct member  106  concentrically with respect to the inner duct member  104 . In this embodiment, the method  300  may further include providing the plurality of jigs  110  within the pre-determined amount of space  108  to connect the outer duct member  106  and the inner duct member  104  such that the pre-determined amount of space  108  between the inner and outer duct members  104 ,  106  is uniform across the cross-sectional area of the duct assembly  102 . 
     As disclosed herein, in an embodiment, the width ‘W’ of the space  108  is based on a desired amount of R-value between the inner and outer duct members  104 ,  106 . 
     In an embodiment, as shown by way of a flowchart for step  304  in the view of  FIG. 4B , the step  304  of providing the bonding and insulation composite  112  within the pre-determined amount of space  108  includes, at step  408   a,  depositing the bonding and insulation composite  112  as flowable media within the pre-determined amount of space  108 , and at step  408   b,  hardening the flowable media into a non-flowable state over a pre-determined period of time prior to installation of the duct assembly  102  within the ducting system  100 . 
     Also, as disclosed earlier by way of embodiments herein, the method  300  may further include using a mixture to form the bonding and insulation composite  112  such that the bonding and insulation composite  112  has an R-value of not less than  13  if the width ‘W’ of the space  108  between the outer and inner duct members  106 ,  104  is 2 inches, i.e., R of approximately 6.8 per inch. Further, the bonding and insulation composite  112  is formed using a closed-cell Polyurethane and resin mixture. Further, this bonding and insulation composite  112  is a thermal and fluid impermeable insulation that is configured to hermetically seal the space  108  between the inner and outer duct members  104 ,  106 . Furthermore, in embodiments herein, the mixture may be poured, or filled, into the space  108  in small increments relative to a length ‘L’ of the duct assembly  102  (refer to  FIG. 1 ). The pouring of the mixture in small increments compared to the length ‘L’ of the duct assembly  102  ensures a complete coverage of the space  108  by the mixture while preventing any air gaps or allowing the inner and/or outer duct members  104 ,  106  to warp or bend when the mixture i.e., the bonding and insulation composite  112  hardens into the non-flowable state. Additionally, as disclosed earlier herein, upon hardening, any excess bonding and insulation composite  112  may be trimmed off from edges of the inner and outer duct members  104 ,  106  so as to allow ends of the composite  112  to be flush with the edges of the inner and outer duct members  104 ,  106 . Additionally, the trimmed ends of the composite  112  that are now flush with the edges of the inner and outer duct members  104 ,  106  could also be sealed off with a coat of paint to enhance the amount of durability of the ducting system  100  so that the ducting system  100  is rendered capable of withstanding and/or enduring forces typically encountered when in transit i.e., when being transported from one location to another. 
     It is hereby envisioned that with implementation and use of embodiments herein, the insulation and bonding composite  112 , once deposited and hardened within the space  108  between the inner and outer duct members  104 ,  106  of the ducting system  100 , can provide added strength to the ducting system  100  so as to allow an exterior surface of the ducting system  100  to be used as a walkway for technicians, or even pedestrians, that may choose to walk on or over an area where the ducting system  100  is installed. Also, with use of the inner and outer duct members  104 ,  106 , the ducting system  100  can be washed and/or cleaned, both on an inside and an outside of the ducting system  100 , using water, other cleaning agents/chemicals, and with any other method commonly known to persons skilled in the art including high pressure washing. 
       FIGS. 5A-5I  are diagrammatic representations illustrating a process of manufacturing the ducting system  100  pursuant to the method of  FIG. 3 . In particular,  FIG. 5A  illustrates a top perspective view of the inner duct member  104 . For manufacturing the ducting system  100 , the process is started by forming the inner duct member  104  to required specifications i.e., a size, shape, and choice of materials, as dictated by one or more drawings, depending on specific requirements for use in a HVAC application. For example, the inner duct member  104  can be formed from suitable metallic materials including, but not limited to, Aluminum, Galvanized steel or Stainless Steel (SS) based on the HVAC application. 
       FIGS. 5B and 5C  illustrate front and top perspective views of the duct assembly  102 . Upon forming the inner duct member  104  as depicted in the view of  FIG. 5A , the outer duct member  106  is formed with the transverse duct flange (TDF)  218  thereon. Moreover, when forming the outer duct member  106 , a size of the outer duct member  106  is selected so as to allow the inner and outer duct members  104 ,  106  to define the pre-determined amount of space  108  therebetween i.e., upon placing the formed outer duct member  106  co-axially with the inner duct member  104 . In order to maintain the co-axial positioning of the outer duct member  106  with the inner duct member  104  i.e., for maintaining a straightness of individual ones of the inner and outer duct members  104 ,  106  and the uniform width ‘W’ of the space  108  between the inner and outer duct members  104 ,  106 , spacing jigs  110  are used (see  FIG. 2 ) between the inner and outer duct members  104 ,  106 . It may be noted that the TDF  218  is integral to the outer duct member  106 . Moreover, the outer duct member  106  may be formed from materials that are similar, or dissimilar, to that used for forming of the inner duct member  104  for purposes of cost, aesthetics, or durability. For example, a pharmaceutical facility that needs to have the inner duct member  104  made from stainless steel for moving a corrosive gas from one location to another does not need the outer duct member  106  to be made necessarily from stainless steel. 
       FIGS. 5D and 5E  illustrate front and top perspective views of the duct assembly  102  provided with the bonding and insulation composite  112  for forming the ducting system  100 . In embodiments of the present disclosure, the bonding and insulation composite  112  is rated at R-6.8 per inch and is a closed cell Polyurethane based pourable foam which hardens to a density that provides at least over 50 pounds per square inch (PSI) when binding the inner and outer duct members  104 ,  106  together. The bonding and insulation composite  112  is waterproof when fully cured. Moreover, the bonding and insulation composite  112  may be ridged when fully cured as the flowable media i.e., the foam mixture is poured in lifts of, for example, 6-10 inches at a time for ensuring complete coverage of the width ‘W’ i.e., without causing air gaps to occur while also preventing the foam from bending one or both of the inner and outer duct members  104 ,  106  as the foam expands and cures within the space  108 . When the insulation composite has cured, it is sawn off, flat, to remain at the level of the duct assembly  102  so that the duct assembly  102  is ready to be joined with an adjacently located duct assembly  102  (see  FIGS. 2 and 5H ). The end of the insulation composite  112  that is flush with the end of the duct assembly  102  may also be sealed off with a coat of protective paint for improved durability of the duct assembly  102  in transit i.e., during shipment. 
       FIG. 5F  illustrates a side perspective view of the ducting system  100  just prior to installing a corner bracket  502  on the ducting system  100 . Each corner of the duct assembly  102  i.e., a space between the outer duct member  106  and the TDF  218  formed thereon is installed with the corner bracket  502 . Upon setting the corner brackets  502  in place, the TDF  218  is crimped around the corner bracket  502  to prevent any relative movement and the installation of the corner bracket  502  to the ducting system  100  is secured in a permanent manner. 
       FIG. 5G  illustrates a side perspective view of the ducting system  100  showing the interfacing gasket  214  being provided thereon. A material of the interfacing gasket  214  is, for example, Butyl rubber that is malleable i.e., flexible and will compress and seal the pair of adjacently located duct assemblies  102   a,    102   b  (see  FIGS. 2 and 5H ) making them air tight. Since each duct assembly  102   a,    102   b  has been formed as a single or unitary piece, the interfacing gasket  214  can be easily located on the TDF  218  of one of the duct assemblies  102   a / 102   b  and advantageously only one interfacing gasket  214  is required for sealing the pair of adjacently located duct assemblies  102   a,    102   b.    
       FIG. 5H  illustrates a side perspective view of the ducting system  100  showing the pair of duct assemblies  102   a,    102   b  being fastened to each other using a plurality of fastening arrangements  504 . For example, as shown in the view of  FIG. 5H , the adjacently located duct assemblies  102   a,    102   b  can be butted up against each other with the interfacing gasket  214  therebetween and the fastening arrangements are installed to pull the two duct assemblies  102   a,    102   b  together for compressing the gasket  214  therebetween. Moreover, as shown, each fastening arrangement  504  may include a carriage bolt  506 , a nut  508  and a washer  510 , but is not limited thereto. As disclosed earlier herein, a type of fastening arrangement  504  used is merely explanatory in nature and hence, non-limiting of this disclosure. In other embodiments, other types of fastening arrangements including, but not limited to, rivets may be suitably employed in lieu of the bolt and nut arrangement disclosed herein. 
       FIG. 5I  illustrates a side perspective view of the ducting system  100  showing TDFs  218  from the pair of adjacently located duct assemblies  102   a,    102   b  being clamped using a plurality of metal cleats  512  for securing the pair of adjacently located duct assemblies  102   a,    102   b.  Each of these cleats  512  is precisely cut and bent to fit tightly over the butted TDFs  218  from the pair of adjacently located duct assemblies  102   a,    102   b.  Once positioned, a crimp tool  514  is used to bend the cleats  512  over the butted TDFs  218  so the only way to remove them would be to bend them back off i.e., in a manner opposite to that used for bending the cleats  512  over the butted TDFs  218 . A number of cleats required for use in securing the butted TDFs  218 , depends on a length of the seams between adjacently located duct assemblies  102   a,    102   b  i.e., along a perimeter of the butted TDFs  218 . In embodiments herein, it is contemplated that these cleats should be installed at intervals of about every 6-10 inches along a perimeter of the butted TDFs  218 . 
     It will be appreciated that features of the present disclosure are susceptible to being combined in various configurations without departing from the scope of the present disclosure as defined by the appended claims. Also, various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art, which are also intended to be encompassed by the following claims. 
     The above description does not provide specific details of manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques known, related art or later developed designs and materials should be employed. Those in the art are capable of choosing suitable manufacturing and design details. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure.