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United States Patent [19] Arnoldt [ii] Patent Number: [45] Date of Patent: 4,662,661 May 5,1987 [54] FLANGE TYPE DUCT JOINT ASSEMBLY AND SEAL ARRANGEMENT THEREFOR [75] Inventor: Peter J. Arnoldt, Puce, Canada [73] Assignee: Ductmate Industries, Inc., Pittsburgh, Pa. [21] Appl. No.: 682,091 [22] Filed: . Dec. 17,1984 Related U.S. Application Data [63] Continuation of Ser. No. 327,934, Dec. 7, 1981, Pat. No. 4,508,376, which is a continuation of Ser. No. 933,179, Aug. 14, 1978, abandoned, which is a con tinuation-in-part of Ser. No. 872,644, Jan. 26, 1978, Pat. No. 4,218,079. [51] Int. Cl.4.............................................. F16L 23/00 [52] U.S. Cl....................................... 285/363; 285/424 [58] Field of Search ............... 285/363, 405, 424, 364 [56] References Cited ' U.S. PATENT DOCUMENTS 565,499 939,001 1,035,810 1,812,319 3,199,901 3,246,918 3,630,549 3,695,636 3,712,650 3,923,326 4,094,520 4,123,094 4,218,079 4,288,115 8/1896 Pattison................................. 285/424 11/1909 Forster etal. . 8/1912 Osborne . 6/1931 Brumfield . 8/1965 Jeppsson ............................... 285/364 4/1966 Burghart ........................... 285/424 X 12/1971 Grimm .............................. 285/424 X 10/1972 Groves.............................. 285/424 X 1/1973 Mez.................................... 285/424 X 12/1975 Mez ........................................ 285/363 6/1978 Rockawayet al. . 10/1978 Smitka ,................................... 285/424 8/1980 Arnoldt . 9/1981 Sullivan.................................. 285/363 FOREIGN PATENT DOCUMENTS 14123 8/1980 1212356 3/1966 2138966 2/1973 2221312 11/1973 2353625 11/1973 7401814 5/1974 2258680 6/1974 2313425 9/1974 2353325 3/1975 2434160 1/1976 European Pat. Off. . Fed. Rep. of Germany .... 285/364 Fed. Rep. of Germany.... 285/424 Fed. Rep. of Germany.... 285/424 Fed. Rep. of Germany . Fed. Rep. of Germany . Fed. Rep. of Germany .... 285/424 Fed. Rep. of Germany .... 285/424 Fed. Rep. of Germany..... 285/424 Fed. Rep. of Germany .... 285/424 2034005 5/1976 2501611 7/1976 2556167 6/1977 2627515 12/1977 1363255 5/1964 1294859 11/1972 1346366 2/1974 1407796 9/1975 Fed. Rep. of Germany Fed. Rep. of Germany Fed. Rep. of Germany Fed. Rep. of Germany France .......................... United Kingdom . United Kingdom . United Kingdom . 285/424 285/424 285/424 285/424 285/424 OTHER PUBLICATIONS Ductwork Connections by the New Labyrinth Flange Joint Section, 3 pages. Smitk Advertisement, "Now You Can Reduce Your In-Place Cost of Duct Connections by 50%". Primary Examiner--Dave W. Arola Attorney, Agent, or Firm--Stanley J. Price, Jr. [57] ABSTRACT A joint assembly for connecting the ends of a pair of generally rectangular sheet metal duct sections includes a pair of frame members secured to each other and connected to the respective duct end sections. The frame members each include four flange portions. Each flange portion has an upstanding channel shaped leg portion and an angularly extending duct receiving leg portion. A corner piece connects adjacent flange por tions and extends into the channel portions of the up standing leg portions to form the generally rectangular frame. The end portions of the ducts are inserted into longitudinal openings of the duct receiving leg portions. A flowing type gasket material is positioned in a longi tudinal pocket of each flange. The end of each duct wall partially displaces the gasket material so that the gasket material extrudes outwardly around the duct wall and between the ends of the flange portion and the corner piece. The surface of the corner piece flange portion is displaced from the front vertical wall of the upstanding channel shaped leg portion so that the edge of the duct extends beyond the flange portion and penetrates an outside gasket member positioned on the upstanding channel shaped leg portion and the comer piece. This provides an effective seal to prevent air within the duct from flowing around the end of the duct and between the outer surface of the duct and the surface of the flange portion of the corner piece. 9 Claims, 11 Drawing Figures U. S. Patent May 5,1987 Sheet 1 of3 4,662,661 U.S. Patent May 5,1987 Sheet 2 of 3 4,662,661 80` 83 74 80 10 U. S. Patent May 5,1987 Sheet 3 of 3 4,662,661 FIG. 10 FIG. // 4,662,661 12 vertical wall of the upstanding channel shaped leg. The FLANGE TYPE DUCT JOINT ASSEMBLY AND arm of the corner piece is arranged to extend into the SEAL ARRANGEMENT THEREFOR opening above the inturned lip so that the corner piece CROSS-REFERENCE TO RELATED APPLICATION arm portion is spaced from the duct end wall by the 5 inturned lip portion. The corner pieces have arms with a curved configuration so that pairs of facing arms in The instant application is submitted with a request for adjacent frames are intended to exert a joinder pressure filing a continuation application under 37 C.F.R. 1.60 of ,on the respective frame when the corner pieces are copending prior continuation application Ser. No. bolted to each other. 327,934 filed Dec. 7, 1981 entitled "A Flange Type 10 In the above joint assemblies, the duct end walls abut Duct Joint Assembly and Seal Arrangement Therefor", either the arm of the corner pieces or abut the inner now U.S. Pat. No. 4,508,376 issued Apr. 2, 1985, which surface of the frame channel shaped leg portion outer is a continuation of application Ser. No. 933,179 filed vertical wall. Where the end of the duct wall rests Aug. 14, 1978, entitled "A Flange Type Duct Assembly against the arm of the corner section, a space is pro and Seal Arrangement Therefor", now abandoned 15 vided between a substantial portion of the outer vertical which is a continuation-in-part of application Ser. No. wall of the channel shaped leg and the end of the duct 872,644 filed Jan. 26, 1978, entitled "Flange Type Duct wall. Where the end of the duct wall is positioned in the Joint Assembly And Method Of Making The Same", space between the inturned lip and the horizontal bot now U.S. Pat. No. 4,218,079 issued Aug. 19, 1980. BACKGROUND OF THE INVENTION tom wall, the duct end wall abuts a portion of the verti 20 cal wall of the frame section between the lip and the horizontal bottom wall. In either instance, irregularities 1. Field of the Invention on the surface of the duct or on the surface of the frame This invention relates to a joint assembly for sealingly portions permit leakage of air from the duct through the connecting the ends of a pair of sheet metal duct sec flange connection. Positioning gasket material on the tions and more particularly to a joint assembly that 25 outer surface of the frame portions does not eliminate includes a pair of frame members having flange portions this air leakage since the leakage is occurring within the secured to each other by angular corner pieces having rearwardly curved or displaced flange portions opera frame portions and around the duct end wall. In German Offenlegungschrift No. 2,221,312 pub ble to facilitate an air-tight seal between the ends of the duct sections and the frame members. 2. Description of the Prior Art 30 lished Nov. 15, 1973, a fibrous gasket material is dis closed as positioned between the upper surface of the U.S. Pat. No. 3,712,650 discloses a flange connection duct end portion and the under surface of the inturned for connecting the ends of rectangular air conditioning rebent portion. French Pat. No. 1,363,255 discloses two ducts that includes flange portions each having a hori pieces of sheet metal joined by a fold arrangement with zontal leg portion secured to the end portion of the duct 35 a sealant engaged to the edge of one of the metal sheets. and a vertical channel shaped leg for receiving the arm U.S. Pat. No. 3,246,918 discloses a flange connection in of an angular corner piece. A wall of the horizontal which sealing is achieved by the penetration of an end flange portion has a sloping intermediate portion that of a duct into a mastic. permits visual access to the bend areas between the One problem encountered with the joint assemblies of adjacent walls of the duct and the ends of tfie duct 40 the prior art is the inability to form an air-tight seal walls. around the duct end wall positioned oppositely of the The angular corner pieces have arm portions which vertical wall of the frame section adjacent the horizon each extend into an opening in the vertical channel tal bottom wall of the frame section. shaped flange. The arm portions are so dimensioned One proposed solution to this problem, as disclosed in vertically that the lower surface of each arm abuts the 45 the German OLS, referred to above, is positioning a lower wall of the horizontal flange. With this arrange longitudinally extending gasket in the longitudinal ment the end of the duct wall abuts or rests against the space between the inturned rebent portion and the surface of the corner piece arm extending into the chan lower wall of the horizontal duct receiving leg. If, when nel shaped opening. the duct end wall is inserted in the duct receiving leg Another joint assembly for connecting the ends of a 50 portion, the gasket material is rolled up against the inner pair of ducts is disclosed in German application No. P surface of the vertical wall of the channel shaped leg 25 56 167 filed Dec. 13, 1975, and includes a plurality of portion, an incomplete seal is formed around the end of flange portions secured to the ends of the ducts and the duct and the inner surface of the bottom wall of the angular corner pieces positioned in vertically extending duct receiving leg portion. Consequently, the end of the channel shaped openings in the respective flange por 55 duct is substantially spaced from the inner vertical wall tions to form a generally rectangular frame secured to of the channel shaped leg portion. An air space is thus the ends of the ducts. The flange portions each have a formed between the outside gasket on the outer surface generally horizontal duct receiving leg and a vertical of the frame portions and the duct edge because the channel shaped leg. The duct receiving leg portion has outside gasket rests on the corner pieces and does not a longitudinal opening for receiving the duct end wall 60 contact the duct edge. This permits air from the duct to and one wall of the vertically extending channel shaped flow around the end of the duct and between the out leg has an inturned or inwardly rebent portion that side surface of the duct and the under surface of the forms a longitudinally extending lip spaced from the corner piece. Thus, air leaks from the ducts at the cor lower wall of the horizontal duct receiving leg. The ners of the frame connecting the ducts. duct end portion is arranged to extend into the space 65 There is need for a joint assembly that provides an between the longitudinally extending lip and the lower effective corner seal between the duct end wall and the wall of the horizontal duct receiving leg. In position, corner pieces that connect the adjacent flanges that the duct end wall abuts the inner surface of the outer form the joint frame. While it has been suggested by the 4,662,661 34 prior art joint assemblies to utilize a longitudinally ex operable to sealingly connect the duct end portion tending gasket in the flange portions to form a seal within the flange portions. The deformable gasket abuts around the duct end portion in the flange portions, the the channel shaped leg portion front wall and the duct gasket inside the flange portions does not prevent leak receiving leg portion bottom wall. The deformable age around the corner pieces adjacent the ends of the 5 gasket means is partially displaced inside the channel flange portions. In addition, even with the use of an shaped leg portion and duct receiving leg portion when outside gasket on the corner pieces, unless the edge of the duct end portion is inserted into the duct receiving the duct abuts the inner surface of the vertical wall of leg portion. With this arrangement, the gasket material the flange portion, the outside gasket does not contact is operable to flow into sealing relation around the edge the end of the duct and air will leak around the end of 10 of the duct end portion in the duct receiving leg por the duct and between the duct and the corner piece tion. beneath the outside gasket. Preferably, the deformable gasket is partially dis SUMMARY OF THE INVENTION placed inside the channel shaped leg portion and the duct receiving leg portion when the duct end portion is In accordance with the present invention there is 15 inserted into the duct receiving leg portion to permit the provided a flange type duct joint assembly to connect edge of the duct end portion to move into abutting the end portions of generally rectangular ducts or duct relation with the front wall of the channel shaped leg sections that includes a plurality of flange portions or portion. The deformable gasket material has a viscosity duct connecting flanges. A plurality of angular corner that permits the material when displaced by movement pieces are provided for connecting adjacent flange por 20 of the duct end portion into the duct receiving leg por tions to form a generally rectangular frame. The flange tion to extrude out of the respective flange portions and portions each have an upstanding channel shaped leg onto the surface of the edge of the duct adjacent to the portion or upstanding corner piece receiving portion corner piece and onto the surface of the corner piece to and a duct receiving leg portion or duct receivng por provide an air-tight seal between the end of the duct tion. The upstanding channel shaped leg portion in 25 adjacent the corner piece and the corner piece at the cludes a front wall and a rear wall forming a corner ends of the flange portions. piece receiving opening therebetween. The duct receiv Further, in accordance with the present invention an ing leg portion includes a top wall and a bottom wall external gasket is positioned in overlying relation with arranged to receive an end portion of a duct therebe the outer surface of the upstanding channel shaped leg tween. The upstanding channel shaped leg portion front 30 portion front wall and the surface of the body of the wall intersects the duct receiving leg bottom wall. The corner section of the corner piece. The external gasket corner pieces each have a body portion or corner sec is penetrated by the corner edge portions of the duct tion and a pair of legs extending angularly therefrom. end portion. The duct corner edge portions extend The corner piece corner section and the legs have a beyond the front surface of the corner piece flange common front planar surface portion and a common 35 portion to provide a seal between the outer surface of rear planar surface portion. The pair of legs are ar the duct edge and the front surface of the corner piece ranged to extend into the corner piece receiving open flange portion to prevent the flow of air therebetween. ings of the flange portion upstanding channel shaped leg Further, in accordance with the present invention the portions. The corner piece body portion includes a front wall of the upstanding channel shaped member corner portion having a flange portion or offset corner 40 has an inner surface arranged to receive in abutting portion extending from the body portion. The corner relation the edge of the duct end portion. The outer section flange portion is in juxtaposition with the up surface of the corner piece flange portion is preferably standing channel shaped leg portion where the front curved or displaced rearwardly away from the front wall of the upstanding channel shaped leg portion inter wall inner surface. With this arrangement the duct end sects the bottom wall of the duct receiving leg portion. 45 portion is permitted to extend beyond the corner piece The corner section flange portion has a front surface flange portion so that the duct edge can penetrate an and a rear surface. The flange portion front surface is external gasket positioned on the surface of the flange displaced from the inner surface of the front wall of the portions and corner pieces. This arrangement provides upstanding channel shaped leg portion. The corner an effective corner seal for the duct joint assembly. piece offset corner portion is positioned externally of 50 Another feature of the present invention is to provide the corner piece receiving openings in the adjacent duct a corner piece for connecting end portions of duct con connecting flange upstanding corner piece receiving necting flanges. The corner piece includes a corner portions. The corner piece corner section offset corner section with a rearwardly displaced flange portion. The portion is displaced rearwardly relative to the corner rearwardly displaced flange portion is arranged to per piece front planar surface and above the duct connect 55 mit the duct corner end portions to project into abutting ing flange duct receiving portion bottom wall. The duct relation with an external gasket and seal the comer edge receiving leg portion is adapted to receive the duct end portions of the duct. portion so that the corner edge portions of the duct end Another feature of the present invention includes a portions extends or projects beyond the corner piece flange type duct joint assembly for connecting the end offset corner portion into abutting relation with an ex 60 portions of generally rectangular ducts or duct sections ternal gasket means positioned on the corner piece cor which assembly includes a plurality of flange portions ner section to provide a seal for the duct corner edge or duct connecting flanges. A plurality of angular cor portion between adjacent duct connecting flange por ner pieces are provided for connecting adjacent flange tions. The external gasket means is positioned in overly portions to form a generally rectangular frame. The ing relation with the duct connecting flange front wall 65 flange portions each have an upstanding channel shaped and a portion of the corner piece corner section. leg portion or upstanding corner piece receiving por A deformable gasket, such as a flowing type gasket tion and a duct receiving portion or a duct receiving leg material, is positioned inside the flange portions and is portion. The upstanding channel shaped leg portion 4,662,661 56 includes a front wall and a rear wall forming a corner duct section corner edge portions to project into sealing piece receiving opening therebetween. The duct receiv relation with an external gasket. ing leg portion includes a top wall and a bottom wall These and other objects of the present invention will arranged to receive an end portion of a duct therebe be more completely disclosed and described in the fol tween. The upstanding channel shaped leg portion front 5 lowing specification, the accompanying drawings, and wall intersects the duct receiving leg bottom wall. The the appended claims. corner pieces each-have a body portion or corner sec tion and a pair of legs extending angularly therefrom. BRIEF DESCRIPTION OF THE DRAWINGS The corner piece corner section and the legs have a FIG. 1 is a fragmentary, exploded perspective view common front planar surface portion and a common 10 of a flange type duct joint assembly for connecting the rear planar surface portion. The pair of legs are ar end portions of a pair of ducts, illustrating a plurality of ranged to extend into the corner piece receiving open angular corner pieces for connecting adjacent flange ings of the flange portion upstanding channel shaped leg portions to form a frame for receiving the end portions portions. The corner piece body portion has a corner of the ducts. portion with a flange portion. The flange portion has an 15 FIG. 2 is an enlarged perspective view of an angular edge or edge portion. The flange portion edge is dis corner piece and adjacent flange portions. placed from the upstanding channel shaped leg portion FIG. 3 is a perspective view of a corner of the end of to permit the edge of the duct end portion to be posi a duct with the flange portions connected thereto and tioned closely adjacent to the intersection of the up the corner piece connecting the adjacent flange por standing channel shaped leg portion front wall and the 20 tions. duct receiving leg bottom wall. The corner piece flange FIG. 4 is a fragmentary perspective view of a corner portion is positioned externally of the corner piece re of the end portion of a duct sealingly connected to a ceiving opening in the adjacent duct connecting flange pair of adjacent flanges connected by a comer piece, upstanding corner piece receiving portion. The corner piece flange edge portion is displaced rearwardly rela tive to the corner piece front planar surface and above the duct connecting flange duct receiving portion bot tom wall so that the duct section corner edge portion, 25 illustrating the edge of the duct extending beyond a flange portion of the corner piece. A deformable gasket material in the flanges is shown extruded from the end of one flange but is omitted from the end of the other flange for purposes of illustration only to more clearly show the relationship between the end of the flange, the between adjacent duct connecting flange portions, 30 flange of the corner piece, and the end of the duct. projects beyond the flange edge portion into abutting FIG. 5 is a perspective view of an angular corner relation with an external gasket means positioned on the piece, illustrating a rearwardly displaced or curved corner piece corner section to provide a seal for the flange portion extending from the inner corner of the duct corner edge portion between adjacent duct con corner piece. necting flange portions. The external gasket means is 35 FIG. 6 is a perspective view of the opposite face of positioned in overlying relation with the duct connect the angular corner piece shown in FIG. 5, illustrating ing flange front wall and a portion of the corner piece the configuration of the rearwardly displaced or curved corner section. This sealing device or external gasket flange portion of the corner piece. means is provided for maintaining an air-tight seal be FIG. 7 is a fragmentary perspective view of a corner tween the outer surface of the duct open end portion 40 piece, illustrating the rearwardly displaced or curved adjacent the comer piece and the edge of the corner flange portion. piece flange portion so that the corner pieces of the FIG. 8 is a fragmentary sectional view of the end generally rectangular frame sealingly engage the duct portion of the duct abutting the front wall of an up end portion to prevent air from within the duct flowing standing channel shaped leg portion of the flange and between the upper surface of the duct and the flange 45 penetrating the gasket member positioned on the flange portion edges of the corner pieces. and the corner piece, illustrating the flange portion of Accordingly, the principal object of the present in the corner piece curved or displaced rearwardly from vention is to provide a flange type duct joint assembly the front wall of the channel shaped leg portion. to connect the end portions of generally rectangular FIG. 9 is a fragmentary sectional view of the end ducts and a plurality of flange portions that are con 50 portions of a pair of ducts connected by the duct joint nected to adjacent flange portions by angular comer assembly of the present invention, illustrating the pieces that are arranged to receive an end portion of a flanges secured to the ducts with the flanges abutting a duct and provide an air-tight seal between the corner gasket therebetween. edge portions of the duct end portion and the surface of FIG. 10 is a sectional view of a corner piece taken the comer piece. 55 along the lines X--X of FIG. 7, illustrating the configu Another object of the present invention is to provide ration of a leg of the corner piece and the curved or a seal arrangement between the end portion of a duct and angular corner pieces that connect a plurality of displaced flange portion of the corner piece. FIG. 11 is a sectional view of a corner piece taken flange portions that form a frame for receiving the duct along lines XI--XI of FIG. 7, illustrating the configura end portion to prevent flow of air from the duct be 60 tion of a comer piece. tween the duct end portion and the comer pieces of the frame. " A further object of this invention is to provide a DESCRIPTION OF THE PREFERRED EMBODIMENT corner piece that permits the duct corner edge portions Referring to the drawings and particularly to FIGS. to project into sealing relation with an external gasket. 65 1-4, there is illustrated the end potion of a pair of duct An additional object of this invention is to provide a sections generally designated by the numeral 10 in flange type duct joint assembly to connect end portions which each duct 10 has a generally rectangular configu of generally rectangular duct sections that permits the ration with an upper duct wall 12, a lower duct wall 14, 4,662,661 78 and a pair of vertical duct sidewalls 16 and 18. The tion 54 has a tear drop configuration in side elevation ducts 10 are formed in the rectangular configuration with an upper leg 56 and a lower leg 58. The legs 56 and illustrated in FIG. 1 with a longitudinally extending 58 extend angularly from the vertical wall 38 and form sealed corner joint 20 between the lower duct wall 14 an acute angle therewith. The lower leg 58 of inturned and the sidewall 16. 5 portion 54 is spaced upwardly from and extends toward As illustrated in FIG. 3, the duct upper wall 12 and the inner surface 60 of the lower horizontal wall 46 to the duct sidewall 18 terminates in end portions having form therebetween a pocket generally designated by the corner portions with corner edge portions 22 and 24. It numeral 62 as seen in FIG. 3. should be understood, although not shown, that the Suitable gasket material 64, as illustrated in FIGS. 2 other duct walls 14 and 16 terminate in similar end 10 and 3, is positioned in the pocket 62 and is maintained portions so that the end portions of the duct 10 extend therein by the angular relation of lower leg 58 of in- along a plane transverse to the longitudinal axis of the turned portion 54 and the bottom horizontal wall 46 and duct 10. the portion of the inner surface 39 of front wall 38 Each of the ducts 10 preferably is fabricated from below the inturned portion 54. The gasket material 64 galvanized sheet material and may have various thick 15 has a viscosity that permits the material to flow into nesses. For example, commercial grade 20 gauge duct position by application from a nozzle into the pocket 62. has a thickness of between 0.906 and 1.106 millimeters. An example material suitable for use as the gasket mate The galvanized surface of the duct walls also provides a rial 64 is a polymeric material, such as Servaseal 5511 relatively irregular surface so that the thickness of the sold by Service Adhesives, Inc. of Maywood, 111. sheet metal forming the duct 10 is not uniform along the 20 Preferably the gasket material 64 remains flowable duct end portions. for a substantial period of time at least during the assem The end portions of the pair of ducts 10 are secured to bly of the duct joint. With this arrangement the end each other by .a pair of frame members generally desig portion of the duct when inserted into the duct receiv nated by the numeral 26. The frame members 26 are ing leg portion 44 partially displaces the gasket material similar in construction and are secured to the ends of 25 within the pocket 62. The gasket material 64 sealingly adjacent duct sections and are connected to each other connects the duct end portion to the respective flanges. by bolts 25 and nuts 27, shown in FIG. 1 as will be Thus, an air-tight seal is formed around the adjacent described later in greater detail. Each frame 26 is metal surfaces as will be explained hereinafter in greater formed by a plurality of duct connecting flanges that detail. extend outwardly from the duct wall end portion and 30 The vertical rear wall 40 of the upstanding channel include an upper flange portion 28, a lower flange por shaped leg portion 36 as seen in FIGS. 3 and 8 extends tion 30 and a pair of side flange portions 32 and 34. The generally parallel to the vertical front wall 38 to a loca configuration of the flange portions 28-34 are identical tion where the inner surface of the rear wall 40 is and are preferably cut to a preselected length from an slightly below the lower leg 58 of inturned portion 54. elongated sheet metal strip that has been roll formed 35 The rear wall 40 at that location is bent to form a junc into the flange configuration illustrated in the drawings. ture with the top wall 48 of the duct receiving leg por Throughout the specification, the flange portions 28 tion 44. The top wall 48 is inclined to and extends into and 34 and the connections therebetween will be de abutting relation with the upper surface of the lower scribed in detail; however, it should be understood that wall 46 which, in turn, is bent upwardly slightly at its the other flange portions are similarly connected to the 40 end portion to receive the duct end wall and frictionally duct end portions and to each other. engage the duct end wall between adjacent surfaces of The flange portion 28 is illustrated in detail in FIGS. walls 46 and 48. The above described configuration 2, 3, 4, 8 and 9. The flange 28 has an upstanding channel permits duct walls of different thicknesses to be utilized shaped corner piece receiving leg portion or upstanding and maintained in frictional engagement between the corner piece receiving portion generally designated by 45 adjacent surfaces of the respective walls 46 and 48. the numeral 36 with a front wall 38 connected to a rear The vertical dimension of the pocket 62 is not critical wall 40 by a generally horizontal top wall 42. A shoul because of the gasket material 64 positioned therein. der 43 is formed between the walls 40 and 42 and is The vertical dimension of pocket 62 may be such that it adapted to receive a longitudinal clip 41 illustrated in is arranged to receive duct end walls of different thick FIG. 9. Extending laterally at substantially a right angle 50 nesses and the flange portions 28-34 may thus be uti from the upstanding channel shaped leg portion 36 is a lized for joint assemblies on ducts of different wall duct receiving leg portion or duct receiving portion thicknesses. It is preferred, as illustrated in FIG. 3, that generally designated by the numeral 44 which has a the duct walls end portions be inserted into the pockets bottom wall 46 and a top wall 48. The top wall 48 has an 62 and through the gasket material 64 until the edges of upturned lip portion 50 to permit the end wall of the 55 the duct wall end portion abut the inner surfaces 39 of duct to slide between the respective walls 46 and 48 so the vertical walls 38. It should be understood that a seal that the duct end wall is frictionally engaged between is obtained when the edge of the duct wall end portions adjacent surfaces of the flange walls 46 and 48. penetrates the gasket material 64. The gasket material In forming the profile of the flange portions, the walls 64 is operable to be displaced and flow out of the pocket 38 and 40 of upstanding leg 36 are spaced from each 60 62 at the end of the respective flanges to thereby form other by the top wall 42 to form a longitudinally extend a seal around the end of the duct at the intersection of ing cavity or corner piece receiving opening 52 for walls 38 and 46 adjacent corner piece 66, as illustrated receiving the legs of angular corner pieces which will in FIG. 4. be described later. The outer vertical wall 38 has an Angular corner pieces 66, as illustrated in FIGS. 1-4 inturned rebent portion generally designated by the 65 and in greater detail in FIGS. 5-7 and 10 and 11, have numeral 54 that extends inwardly into the opening 52 a generally planar configuration. Each comer piece 66 closely adjacent the inner surface of vertical wall 40. As has a corner section or body portion 70 and legs 72 and illustrated in greater detail in FIG. 8, the inturned por 74 extending angularly therefrom in substantially the 4,662,661 9 10 same plane as the corner section 70. The legs 72 and 74 portion to extend beyond the edge portion 95 and the are arranged to extend into the openings 52 of flange surface 91 of flange portion 85 permitting the duct end portions 28 and 34 while the corner section 70 remains portion to be positioned closely adjacent to or in abut outside of the flange portion openings 52, as illustrated ting relation with the inner surface 39 of the flange front in FIGS. 1-4. The corner piece 66 has a front planar 5 wall 38. With this arrangement an air-tight seal is pro surface 73 and a rear planar surface 75. The front planar vided around the corner edge portions 22 and 24 adja surface 73 within the flange portion openings 52 is ar cent the flanges 28 and 34 by the penetration of the duct ranged to abut the inner surface 39 of the frame front edge portions 22 and 24 into a gasket 106, positioned on wall 38. Also, as illustrated in FIGS. 5 and 6, for exam the corner piece corner section 70, as illustrated in FIG. ple, corner piece corner section 70 has a common front 10 4 and as will be explained later in greater detail. planar surface portion and a common rear planar sur As illustrated in FIG. 11, the leg 72 of corner piece face portion with leg 72 and corner piece corner section edges 90 and 92. When the leg 72 is positioned in the 70 has a common front planar surface portion and a opening 52 of flange portion 28, as illustrated in FIGS. common rear planar surface portion with leg 74. The 3 and 8, the upper edge 90 of leg 72 abuts the under corner piece 66 has an elongated embossed portion 76, 15 surface of the horizontal wall 42 and the lower edge 92 as illustrated in FIGS. 5, 6, 10 and 11 which extends abuts upper leg 56 of the inturned portion 54. The rear from a location adjacent the end portion 78 of the leg 72 convex surface 79 of the embossment 76 abuts the inner to the corner section 70 and continues through the cor surface of the rear wall 40 while the planar front surface ner section 70 along the other leg to a location adjacent 73 of the leg abuts the inner surface 39 of the front wall the end portion 80 of leg 74. The embossed portion 76 20 38. With this arrangement, the leg 72 of the corner piece has a front concave surface 77 and a rear convex surface 66 abuts the surfaces of both the front wall 38 and rear 79. The convex surface 79 within the flange portion wall 40 in the cavity 52 and the upper edge 90 abuts the openings abuts the front surface of the flange rear wall horizontal .wall 42 while the lower edge 92 abuts the 40. With this arrangement, the legs 72 and 74 have a surface of the inturned portion upper leg 56. This pro front planar surface 73 that abuts the rear surface 39 of 25 vides a rigid, sturdy connection between the corner flange front wall 38 and a convex surface 79 that abuts piece leg portion and the flange portion. the inner surface of rear wall 40. As above described, the shoulders 88 and 96 are ar The legs 72 and 74 have apertures 82 therein to per ranged to abut the ends 102 and 104 of the flange por mit dimpling of the frame portions after assembly of the tions 28 and 34 so that the lower corner portion 83 of frame member 26. The corner section 70 has a bolt 30 the corner piece corner section 70 does not extend into aperture 84 arranged to receive a connecting bolt. The the longitudinal openings 52 of the respective flange corner piece 66 has shoulders 86 and 88 adjacent the portions. Therefore, the rearwardly curved or dis upper and lower edges 90 and 92 of leg 72 and shoulders placed flange portion 85 of the comer portion 83 is in 94 and 96 adjacent the upper and lower edges 98 and juxtaposition with the flange portion ends 102 and 104. 100 of leg 74, defining the boundary of the corner piece 35 Further, as illustrated in FIGS. 4 and 8 the front surface corner section 70 relative to legs 72 and 74. The shoul 91 of the arcuate flange portion 85 along the edge 95 is ders 86, 88, 94 and 96 serve as a stop means and operable spaced rearwardly from the inner surface 39 of the as stops arranged to abut ends 102 and 104 of flange flange portion front wall 38. The longitudinal edge 95 portions 28 and 34, as illustrated in FIG. 3 to limit the also is spaced above the horizontal inner surface 60 of length the legs 72 and 74 extend into the flange portions 40 the flange bottom wall 46. With this arrangement, clear 28 and 34. The corner piece corner section 70 has a ance is provided between the L-shaped edge 95 of the lower corner portion generally designated by the nu corner piece flange portion 85 and the bottom wall meral 83 having an L-shaped flange or offset portion 85, upper surface 60 to permit the duct end portions to pass as illustrated in FIGS. 7 and 10. The flange portion 85 between the duct receiving walls 46 and 48 into abut has an arcuate or offset portion 89 which is displaced or 45 ting relation with the inner surface 39 of the flange front curved rearwardly in a direction away from the corner wall 38 and the corner edge portions 22 and 24 to pass piece front planar surface 73 toward the rear planar beyond the longitudinal edge 95 and flange surface 91. surface 75. The flange arcuate portion 89, as illustrated With this arrangement, as illustrated in FIG. 4, the end in FIGS. 5-7, has a front surface 91, a rear surface 93, portions of the duct 10 extend into the flange portions of and an L-shaped end or edge portion 95 which is dis 50 the frame member 26 with the exception of the L- placed rearwardly from the front planar surface 73. The shaped corner portions of the duct. The exposed por edge portion 95 extends from the shoulder 88 to the tions of the duct corner edge portions 22 and 24 are not . shoulder 96. The flange 85 is thus bounded by the shoul embedded in the mastic seal and it is essential that a seal ders 88 and 96 and the L-shaped edge portion 95. be provided along these exposed corner edge portions With the above described arrangement of the corner 55 22 and 24 of the duct: Thus, the plane corner edges 22 piece 66, the leg portions 72 and 74 are positioned in the and 24 of the duct end portions extend beyond the edge openings 52 of flange portions 28 and 34. The top walls portion 95 of the corner piece lower corner portion 42 of the upstanding channel shaped leg portions 36 flange 85 into the surface of the gasket 106. serve as a stop means and abut shoulders 86 and 94 to The frame members 26 are formed by first cutting prevent the corner section 70 of the corner piece 66 60 preselected lengths of the strips having preformed from extending into the longitudinal openings 52. With flange portion profiles. For example, frame portions 28, the corner piece 66 in this position as illustrated in FIG. 30, 32 and 34 are cut from a strip of the flange shaped 8, the front surface 91 and L-shaped edge 95 of the profile. Four corner pieces 66 have the leg portions 72 rearwardly or displaced curved flange or offset portion and 74 inserted in the openings 52 in the respective 85 are displaced rearwardly from the inner surface 39 of 65 upstandng channel shaped leg portion 36 so that they the front wall 38 and spaced above the upper surface of extend into the openings 52 their entire length with the horizontal bottom wall 46 so as to provide clearance for shoulders 86, 88, 94 and 96 abutting the edges of the the comer edge portions 22 and 24 of the duct end respective flange portions. With the corner pieces 66 4,662,661 11 12 secured in the openings, the generally rectangular frame member 106 which is positioned between the upstand 26 is then secured to the end of the duct 10 by passing ing channel shaped leg portions 36 in overlying relation the duct walls 12-18 between the legs 46 and 48 of the with the corner piece lower corner portions 83. In this duct receiving leg portion 44. The end portions of the manner air from within the duct is prevented from flow respective duct walls 12-18 are urged into the flange 5 ing around the duct end wall and between the upper portions 28-34 until the duct end wall portions pene surface of the duct and the surface of the corner piece trate the gasket material 64 and abut the inner surfaces flange edge 95. 39 of the frame portion vertically extending walls 38. According to the provisions of the patent statutes, I It will be apparent that due to variations in the thick have explained the principle, preferred construction, ness of the duct end wall portions, the duct end portions 10 and mode of operation of my invention and have illus may be spaced slightly from the front wall 38 but trated and described what I now consider to represent closely adjacent thereto to the extent that the edge of its best embodiments. However, it should be understood the duct displaces the gasket material 64 in the pocket that, within the scope of the appended claims, the inven 62. Consequently, the flowing type gasket material ex tion may be practiced otherwise then as specifically trudes outwardly around the upper and lower surfaces 15 illustrated and described. of the duct wall portions to seal the end portion of the I claim: duct wall in the respective pocket 62 of the flange por 1. A corner piece for connecting a pair of duct con tion. Further, a portion of the gasket material 64 ex necting flange members comprising, trudes longitudinally, as illustrated in FIG. 4, beyond a corner section with a pair of legs extending angu the ends of the flange portions adjacent the corner piece 20 larly therefrom, corner portion 83. The gasket material 64 flows be said corner section and said legs having a common tween a respective corner piece shoulder portion, for front planar surface portion and a common rear example shoulder 88, and the adjacent flange end por planar surface portion, . tions and onto the flange portion 85. Further when the said legs arranged to extend into said duct connecting gasket material 64 is extruded from the open end of the 25 flange members to form a generally rectangular flange it flows into the space between the upper surface duct frame for connection to a duct end portion, of the end of the duct wall and the edge 95 of the corner said corner section having an offset corner portion piece flange portion 85. This arrangement provides an displaced rearwardly from said common front pla effective air-tight seal between the flange and the duct nar surface portion, and and the corner piece and the duct with the flange. For 30 said corner section offset corner portion and said purposes of illustration only the gasket material 64 has corner section front planar surface being operable been omitted from flange portion 34 shown in FIG. 4. to permit a corner edge portion of the duct end As illustrated in FIG. 9, pairs of ducts are positioned portion positioned between the end portions of with the flange members in abutting relation with each adjacent duct connecting flange members to other. A suitable relatively thin gasket member 106 such 35 project beyond said offset corner portion into abut as neoprene, polyethylene or the like, is positioned be ting relation with an external gasket means and said tween the upstanding channel shaped leg portion front corner section front planar surface in abutting rela walls 38 on the outer surface 37 thereof and between the tion with said gasket to seal the comer edge por surfaces of the corner pieces 66. Preferably, the gasket tion of the duct. member 106 is formed or shaped to meet the dimensions 40 2. A corner piece for connecting a pair of duct con of the duct end wall and the respective frame members necting flange members as set forth in claim 1 in which, 26. Bolts 25 are inserted through the respective aper said offset corner portion has a generally L-shaped tures 84, and nuts 27 are threadedly secured to the bolts configuration with opposite end portions, and 25 to thus secure the corner pieces 66 to each other and, said offset comer portion arranged to be spaced in turn, secure the respective frame members 26 to each 45 above a duct connecting flange duct receiving other with the ducts 10 secured thereto. portion bottom wall. With this arrangement, the frame members 26 pro 3. A corner piece for connecting a pair of duct con vide a joint assembly for securing the duct members 10 necting flange members as set forth in claim 1 in which, to each other and to form an air-tight seal therebetween. said offset corner portion has a generally L-shaped The configuration of the flange portions permits duct 50 configuration defined by a front surface and a rear members having walls of different thicknesses to be surface forming an edge portion therebetween, and utilized with the frame portions having the same dimen said offset corner portion edge portion positioned sion. The edges of the duct walls extend into the flow rearwardly of said common front planar surface ing type gasket material 64 in the longitudinal openings portion. 52 to provide an air-tight seal between the undersurface 55 4. A comer piece for connecting a pair of duct con of the duct wall and the uppersurface of the duct receiv necting flange members comprising, ing leg portion and further around the duct end wall . a corner section with a pair of legs extending angu between the upper-surface of the duct wall and the larly therefrom, innersurface 39 of front wall 38. In addition the flowing said corner section and said legs having a common type gasket material 64 is effective to form an air-tight 60 front planar surface portion and a common rear seal where the surfaces of duct walls or the walls of the planar surface portion, frame portions are irregular due to the coating applied said corner section having a corner portion, to the surface during the galvanizing operation. a flange portion extending from said comer section Further it will be apparent from the present invention corner portion, said flange portion having an end that by rearwardly curving or displacing the corner 65 portion displaced rearwardly from said common piece flange portions 85 that form the corner piece front planar surface portion, and corner portion 83, the duct corner edge portions 22 and said corner section front planar surface and said 24 are operable to extend into or penetrate the gasket flange portion end portion being operable to permit 4,662,661 13 . 14 a corner edge portion of a duct end portion posi said flange portion L-shaped edge portion being off tioned between the end portions of adjacent duct set at an angle less than 90 from said comer section connecting flange members to project beyond said front surface so that said L-shaped edge extends flange end portion into abutting relation with an rearwardly in a direction from said corner section externa] gasket means and said corner section front 5 front surface to said corner section rear surface. planar surface in abutting relation with said gasket 7. A corner piece for connecting a pair of duct con means to seal the corner edge portion of the duct. necting flange members as set forth in claim 6 in which, 5. A corner piece for connecting a pair of duct con said flange portion offset L-shaped edge extends necting flange members as set forth in claim 4 in which, along a curved path rearwardly from said corner said flange portion has a generally L-shaped configu 10 section front surface. ration with opposite end portions, and 8. A corner piece for connecting a pair of duct con necting flange members as set forth in claim 6 in which, said flange portion end portion arranged to be spaced said pair of legs each has a front surface and a rear above a duct connecting flange receiving portion surface, bottom wall. 15 said corner section front surface and said legs front 6. A corner piece for connecting a pair of duct con surfaces having portions positioned in a common necting flange members comprising, plane to form a common front planar surface, and a corner section having a front surface, said corner section rear surface and said legs rear a pair of legs extending angularly from said corner surfaces having portions positioned in a common section, 20 plane to form a common rear planar surface. said corner section having a corner portion with a 9. A corner piece for connecting a pair of duct con flange portion having an L-shaped edge portion, necting flange members as set forth in claim 8 in which, said flange portion having a front sealing surface said flange portion offset L-shaped edge is displaced arranged to abut an external gasket means to seal the corner portion of the duct, and 25 rearwardly from said common front planar surface. ***** 30 35 40 45 50 55 60 65 IIIHIHHIIIIIIII US004662661B1 REEXAMINATION CERTIFICATE (3188th) United States Patent m tm Bl 4,662,661 Amoldt [45] Certificate Issued May 13, 1997 [54] FLANGE TYPE DUCT JOINT ASSEMBLY AND SEAL ARRANGEMENT THEREFOR [75] Inventor: Peter J. Amoldt, Puce, Canada [73] Assignee: Ductmate Industries, Inc., Pittsburgh, Pa. Reexamination Request: No. 90/004370, Sep. 16, 1996 Reexamination Certificate for: Patent No.: 4,662,661 Issued: May 5,1987 Appl. No.: 682,091 Filed: Dec. 17,1984 Related U.S. Application Data [63] Continuation of Ser. No. 327,934, Dec. 7, 1981, Pat No. 4,508,376, which is a continuation ofSer. No. 933,179, Aug. 14,1978, abandoned, which is a continuation-in-part of Ser. No. 872,644, Jan. 26, 1978, Pat No. 4,218,079. [51] InLCI.6 ................................................ F16L 23/00 [52] U.S. Cl...........................................285/363; 285/424 [58] Field of Search ................................. 285/363, 364, 285/405, 424 [56] References Cited U.S. PATENT DOCUMENTS 565,499 939,001 1,035,810 1,812,319 3,199,901 3346,918 3,630,549 3,695,636 3,712,650 3,923,326 4,094,520 4,123,094 4218,079 4288,115 4,508,376 8/1896 Pattison..................................... 285/424 11/1909 Forster et al. . 8/1912 Osborne. 6/1931 Brumfield. 8/1965 Jeppsson ................................... 285/364 4/1966 Burghart ............................... 285/424 X 12/1971 Grimm .................................. 285/424 X 10/1972 Groves .................................. 285/424 X 1/1973 Mez ...................................... 285/424 X 12/1975 Mez ........................................... 285/363 6/1978 Rockaway et al. . 10/1978 Smitka ....................................... 285/424 8/1980 Amoldt. 9/1981 Sullivan ..................................... 285/363 4/1985 Amoldt ...................................... 285/363 4,584,756 4/1986 Amoldt .................................... 29/526 R FOREIGN PATENT DOCUMENTS 14123 1363255 1212356 8/1980 European Pat. Off. . 5/1964 France ....................................... 285/424 3/1966 Germany .................................. 285/364 (List continued on next page.) OTHER PUBLICATIONS Ductwork Connections by the New Labyrinth Flange Joint Section, 3 pages. SmitkAdvertisement, "Now You Can Reduce Your In-Place Cost of Duct Connections by 50%". Schmolz & Bickenbach Catalog. Technischer & Hinweis Drawings. Primary Examiner--Dave W. Arola [57] ABSTRACT A joint assembly for connecting the ends of a pair of generally rectangular sheet metal duct sections includes a pair of frame members secured to each other and connected to the respective duct end sections. The frame members each include four flange portions. Each flange portion has an upstanding channel shaped leg portion and an angularly extending duct receiving leg portion. A comer piece con nects adjacent flange portions and extends into the channel portions of the upstanding leg portions to form the generally rectangular frame. The end portions of the ducts are inserted into longitudinal openings of the duct receiving leg portions. A flowing type gasket material is positioned in a longitudinal pocket of each flange. The end of each duct wall partially displaces the gasket material so that the gasket material extrudes outwardly around the duct wall and between the ends of the flange portion and the corner piece. The surface of the comer piece flange portion is displaced from the front vertical wall of the upstanding channel shaped leg portion so that the edge of the duct extends beyond the flange portion and penetrates an outside gasket member positioned on the upstanding channel shaped leg portion and the comer piece. This provides an effective seal to prevent air within the duct from flowing around the end of the duct and between the outer surface ofthe duct and the surface of the flange portion of the comer piece. B1 4,662,661 Page 2 FOREIGN PATENT DOCUMENTS 2138966 2221312 2353625 7401814 2258680 2313425 2353325 2/1973 Germany .................................. 285/424 11/1973 Germany .................................. 285/424 11/1973 Germany. 5/1974 Germany. 6/1974 Germany. 9/1974 Germany ................................... 285/424 3/1975 Germany ................................... 285/424 2434160 2034005 2501611 2556167 2627515 1294859 1346366 1407796 1/1976 5/1976 7/1976 6/1977 12/1977 11/1972 2/1974 9/1975 Germany ....................... .......... 285/424 Germany ....................... .......... 285/424 Germany ....................... .......... 285/424 Germany ....................... .......... 285/424 Germany ....................... .......... 285/424 United Kingdom . United Kingdom . United Kingdom . B1 4,662,661 12 REEXAMINATION CERTIFICATE ISSUED UNDER 35 U.S.C. 307 NO AMENDMENTS HAVE BEEN MADE TO THE PATENT AS A RESULT OF REEXAMINATION, IT HAS BEEN DETERMINED THAT: The patentability of claims 1-9 is confirmed.