Patent Publication Number: US-7594518-B2

Title: Vane assembly for HVAC duct systems

Description:
This invention pertains to heating, ventilation, and air conditioning (HVAC) duct systems that utilize components fabricated from sheet metal and other panel material. 
   More particularly, the invention pertains to a vane assembly that includes a plurality of spaced apart parallel vanes and that is incorporated in a HVAC duct system to direct the flow of air around a corner in the duct system. 
   In a further respect, the invention pertains to a vane assembly that, once constructed, is unlikely to come apart, that maintains a desired parallel relationship between vanes in the system, and that prevents vane ends from twisting. 
   The use of vane assemblies in HVAC duct systems is well known. Such vane assemblies are used to smoothly direct a stream of air around an “elbow” or corner in the HVAC duct system. One typical hollow duct elbow  10  is, by way of example, illustrated in  FIG. 1 . Conventional vane assemblies include a plurality of arcuate spaced apart vanes  12 ,  13  mounted on and intermediate a pair of parallel, spaced apart runners  11 . The size of the vanes and accompanying runners can vary as desired. The vanes  15  and  16  in  FIG. 3  are smaller than vanes  12 ,  13 . The runners  17  ( FIGS. 5 and 6 ) used in combination with vanes  12 ,  13  are smaller than runners  11 . Vanes  12 ,  13 ,  15 ,  16  each consist of a pair of arcuate metal pieces. In contrast, vanes  18  and  19  in  FIG. 4  each consist of a single arcuate piece of metal. As is indicated in  FIG. 7 , the upper and lower ends of conventional vanes  12  are typically bolted, screwed, or welded to runners  11 . 
   One disadvantage of conventional vane assemblies of the type set forth in  FIGS. 1 to 7  is that the vane ends tend to come apart from the runners, particularly when a “button punch” is used. Another disadvantage of conventional vane assemblies is that bolting, screwing, or welding each end of a vane to its associated runner is time consuming. A further disadvantage of conventional vane assemblies is that two-piece vanes of the type illustrated in  FIGS. 2 and 3  tend to slide and the ends of the vanes tend to twist. 
   Accordingly, it would be highly desirable to provide an improved vane assembly that reduces the time required to assemble the vane system, and that reduces the likelihood that the vane system will come apart lose its desired configuration. 
   Therefore, it is a principal object of the instant invention to provide an improved vane assembly for use in directing air flow through a corner in a HVAC duct assembly. 
   Another object of the invention to provide an improved vane assembly that does not require vanes to be bolted, screwed, or welded to their associated runners. 
   A further object of the invention is to provide an improved vane system that maintains its structural integrity. 

   
     These and other, further and more specific objects and advantages of the invention will be apparent from the following detailed description of the invention, taken in conjunction with the drawings, in which: 
       FIG. 1  is a perspective view illustrating a conventional rectangular corner utilized in a conventional HVAC duct assembly; 
       FIG. 2  is a top view illustrating a pair of conventional vanes positioned with respect to a runner attached to the lower ends of the vanes; 
       FIG. 3  is a top view illustrating another pair of conventional vanes positioned with respect to a runner attached to the lower ends of the vanes; 
       FIG. 4  is a top view illustrating a further pair of conventional vanes positioned with respect to a runner attached to the lower ends of the vanes; 
       FIG. 5  is a top view illustrating a runner of the type utilized in  FIG. 3 ; 
       FIG. 6  is an end view further illustrating the runner of  FIG. 5 ; 
       FIG. 7  is a perspective view illustrating a conventional vane system consisting of parallel, spaced apart vanes each having an upper end attached to one runner and a lower end attached to another runner; 
       FIG. 8  is a top view generally illustrating an end of a unitary vane constructed in accordance with the invention; 
       FIG. 9  is a top view generally illustrating an end of a unitary vane constructed in accordance with the invention; 
       FIG. 10  is a top view illustrating a runner constructed in accordance with invention; 
       FIG. 11  is a perspective view illustrating a runner tongue in position to be inserted in one end of a vane; 
       FIG. 12  is a perspective view illustrating the runner tongue of  FIG. 11  being inserted in interlocking engagement with the vane of  FIG. 11 ; 
       FIG. 13  is a perspective view illustrating the teeth on the runner tongue and the openings in the vane ribs; 
       FIG. 14  is a perspective view illustrating the runner tongue teeth in interlocking engagement with the openings in the vane ribs; 
       FIG. 15  is a view of one end of a vane further illustrating the runner tongue inserted in interlocking engagement with the other end of the vane; 
       FIG. 16  is an exploded perspective view illustrating vanes constructed in accordance with the invention positioned to be assembled with a pair of runners each positioned at the top or bottom of the vanes; and, 
       FIG. 17  is a perspective view illustrating the runners and vanes of  FIG. 16  in the completed vane assembly. 
   

   Briefly, in accordance with my invention, I provide improvements in combination with a corner in a duct in a HVAC assembly. The improvements direct a flow of air through the corner and comprise a vane system. The vane system includes a plurality of unitary vanes each including at least one arcuate wall with a pair of sides; an upper end; a lower end; and, at least one rib intermediate the sides and extending intermediate the ends. The vane system also includes a first runner connected to the upper ends of the vanes; and, a second runner connect to the lower ends of the vanes. 
   In another embodiment of the invention, I provide a vane system for use in a corner in a duct in a HVAC assembly to direct a flow of air through the corner, the vane system comprises a plurality of unitary vanes each including at least one arcuate wall with a pair of sides; an upper end; a lower end; and, at least one rib intermediate the sides, extending intermediate the ends, and including at least one aperture formed therethrough. The vane system also includes a first runner connected to the upper ends of the vanes and including a plurality of tongues. Each of the tongues extends along a different one of the vanes and has at least one tooth extending through and interlocking with the aperture in the one of the vanes. The vane assembly also includes a second runner connected to the lower ends of the vanes. 
   In a further embodiment of the invention, I provide a method for constructing a vane system for use in a corner in a duct in a HVAC assembly to direct a flow of air through the corner. The method includes the step of providing a plurality of unitary vanes each including at least one arcuate wall with a pair of sides; an upper end; a lower end; and, at least one rib intermediate the sides, extending intermediate the ends, and including at least one aperture formed therethrough. The method also includes the steps of providing a first runner including a plurality of spaced apart tongues each having at least one tooth, the tongue shaped and dimensioned to slidably insert in one of the vanes such that the tooth extends through and interlocks with the aperture in the one of the vanes; providing a second runner; connecting the lower ends of the vanes to the second runner; and, sliding each of the tongues of the first runner into a different one of the vanes such that the tooth on each of the tongues interlocks with one of the apertures. 
   Turning now to the drawings, which depict the presently preferred embodiments of the invention for the purpose of illustrating the practice thereof and not by way of limitation of the scope of the invention, and in which like reference characters refer to corresponding elements throughout the several views,  FIG. 8  generally illustrates a vane constructed in accordance with the invention and generally indicated by reference character  20 . The vane  20  includes a first arcuate portion  21  and a second arcuate portion  22 . Portions  21  and  22  co-terminate at ends  23  and  24 . The units of measure for the numbers shown in  FIG. 8  (i.e., 2.828, 0.375, etc.) is inches. 
     FIG. 9  generally illustrates a vane constructed in accordance with the invention and generally indicated by reference character  25 . The vane  25  includes a first arcuate portion  26  and a second arcuate portion  27 . Portions  26  and  27  co-terminate at ends  28  and  29 . The units of measure for the numbers shown in  FIG. 9  (i.e., 0.500, 1.208, etc.) is inches. 
     FIG. 10  illustrates a runner  30  constructed in accordance with the invention and including a plurality of tongues  34  each extending into an opening  31  formed through runner  30 . Since runner  30  is typically, although not necessarily, produced from sheet metal, openings  31  are usually formed with a punch in a flat panel shaped piece of material. The middle tongue  34  in  FIG. 10  has been bent upwardly along a fold line  40  such that the middle tongue is normal to the plane of the sheet of paper of the drawing and is normal to runner  30 . Prior to using runner  30 , each of the remaining tongues  34  is bent along fold line  40  to a position normal to the plane of the sheet of paper of the drawing. 
   The ribs  38 ,  39  provided in each vane  25  are illustrated in  FIG. 11 , as are the apertures  41  formed through each rib  38 ,  39 . Apertures  41  are spaced apart from portion  26  of vane  25 . Each tongue  34  includes one wing or flange  65  provided with teeth  37  and a second wing or flange  66  provided with teeth  38 . Tongue  34  also includes panel sections  63 ,  64 ,  67 .  FIG. 11  illustrates tongue  34  prior to its being slid into vane  25 . In  FIG. 12 , tongue  34  is in the process of being slid into vane  25  in the direction of arrows A such that each tooth  37  interlocks with an aperture  41 . 
   The presently preferred configuration of ribs  38  and  39 , of apertures  41  formed through ribs  38  and  39 , and of teeth  37  is more specifically illustrated in  FIGS. 13 and 14 . Each rib  38  includes a base portion  80  and a leg portion  81 . The angle B between portions  80  and  81  can be varied as desired but preferably is less than one hundred and eighty degrees and, consequently, tends to form at the juxtaposition of portion  80  and  81  a “V” groove that opens toward teeth  37  and along which the outer edges  43  of teeth  37  slide when tongue  34  is being slidably inserted along a vane  25 . The bottom edges  82 ,  85  of each aperture  41  slope downwardly to a juxtaposition  84  to also form a “V” groove. The lower edge  44  of a tooth  37  seats at juxtaposition  84  in the manner illustrated in  FIG. 14  when tooth  44  extends through aperture  41 . 
   Upper sloped edge  42  of tooth  37  is at an angle D to vertical edge  87  that is greater than ninety degrees, preferably is greater than one hundred ten degrees, and most preferably is greater than one hundred and thirty-five degrees. This sloped edge  42  facilitates the sliding of teeth  37  along a rib  38 ,  39  when tongue  34  is inserted in a vane  25 . In contrast, the lower edge  44  of a tooth  37  is preferably at an angle C from vertical edge  87  that is less than ninety degrees. Edge  87  is generally parallel to rib  38 . When edge  44  is at an angle C that is less than ninety degrees, once tongue  34  is inserted in a vane  25  and teeth  37  each extend through an aperture  41 , attempting to withdrawn tongue  34  in a direction opposite of that arrow B from vane  25  only functions to better seat in the juxtaposition  84  of each aperture  41  the portion of tooth  37  at the function of lower edge  44  and vertical edge  87 . Pulling tongue  34  in a direction opposite that of arrow B generates a force that function to force lower edge  44  into aperture  41  and through its associated aperture  41  in the direction indicated by arrow T in  FIG. 14 . 
   When tongue  34  is being slid into a vane  25 , vane  25  and/or tongue  34  resiliently deform to permit outer edges  43  to slid along rib  38  (or  39 ) until each tooth  37  is lodged in and extends through its associated desired aperture  41  and is in the position illustrated in  FIG. 14 . One way vane  25  can resiliently deform is by permitting edges  43  to displace a rib  38  in a direction E outwardly away from teeth  37 . After each tooth  37  is lodged, or “snaps into” in an aperture  41 , rib  38  resiliently moves in a direction opposite that of arrow E back to its normal position and orientation in vane  25 . Or, tongue  34  can resiliently deform by flexing inwardly in the direction of arrow F. After each tooth  37  is seated in an aperture  41  in the manner illustrated in  FIG. 14 , tongue  34  can “unflex” and resiliently move in a direction opposite that of arrow F back to the normal configuration illustrated in  FIGS. 14 ,  11 ,  15 . Vane  25  and/or tongue  34  can be configured and constructed in any desired manner that permits tongue  34  to be slidably inserted in vane  25  in the manner illustrated in  FIGS. 11 to 17 . 
   A tongue  34  fully inserted in a vane  25  is illustrated in  FIGS. 15 and 17 . In  FIG. 15 , the juncture  50  of wing  65  and portion  63  contacts the inner surface of arcuate portion  26 ; the juncture  51  of wing  66  and portion  64  contacts the inner surface or arcuate portion  26 ; and, portion  67  contacts section  49  of vane  25 . These three contact points, along with the points at which teeth  37  contact ribs  38  and  39  while being inserted in vane  25  and after being inserted in vane  25 , serve to guide tongue  34  into vane  25  and to improve the structural integrity of the vane assembly after each tongue  34  is fully inserted in one end of a vane  25 . 
   Although the number of separate pieces of material used to form a vane  25  can vary as desired, the presently preferred vane configuration utilizes and bends a single piece of material to form a vane  25  that includes one or more ribs  38 ,  39 . The ends or sides of the single pieces of material are wrapped  49  or otherwise secured together. Ribs  38 ,  39  improve the rigidity and structural integrity of vane  25  and reduce the likelihood that the vane  25  will warp or twist, particularly after a tongue  34  is inserted in each end of vane  25 . 
   In use, vanes  25  and runners  30  are provided. Tongues  34  are slidably inserted in each end of vane  25  in the manner illustrated in  FIGS. 16 and 17  to form a vane assembly illustrated in  FIG. 17  wherein each tooth  37  extends into, and preferably through, an aperture  41  in an associated rib  38 ,  39 . Each tooth  37 , after being inserted in an aperture  41 , preferably interlocks in some manner with aperture  41  to make removal of a tooth  37  from aperture  41  difficult. The completed vane system of  FIG. 17  is installed in a corner  10  in a HVAC duct assembly in conventional fashion in the manner indicated by dashed lines  101  in  FIG. 1  to facilitate and direct air flow through and around the interior  100  of corner  10 . Bolts, welds, screws or another other desired means are used to secure the vane system inside corner  10 . The shape and dimension of corner  10  can vary as desired. Similarly, the shape and dimension of vanes  25  and runners  30  can vary as desired such that the vane system can be integrated in a selected corner  10  to direct the flow of air through the hollow interior of corner  10 .