Catalytic converter front flange and method of making same

A replacement flange for the end of a catalytic converter is provided by a pair of generally L-shaped coupling elements which have their base portions opposed and seated in an elongated channel element which permits one coupling element to slide therein relative to the other.

The opposed edges of the flange coupling elements are generally arcuate to fit about the end pipe of the converter and have recesses to seat the flanges on the sides of the converter body. Assembly is effected by mounting one coupling element to the automobile support structure about the converter end and then sliding the other coupling element sideways into engagement therewith and mounting it to the support structure.

The present invention relates to replacement flanges for catalytic converters, and, more particularly, to such flanges which can be readily assembled by the mechanic about the catalytic converter and to the flange for the exhaust system without extensive disassembly and while all the parts are relatively hot.

As is well known, the catalytic converters on most vehicles are supported by original equipment flanges which are custom designed for a given vehicle, and which are frequently of one piece construction. Unfortunately, corrosion and heat cycling may cause failure of the flanges while the converter is still functional, and cause failure of the connection to the exhaust system. Unless promptly replaced, the converter itself may be damaged and repair of the sealed converters is impracticable.

Replacing the flanges with original equipment flanges may require some disassembly of the exhaust system in order to provide sufficient space for maneuvering the replacement flange into position, and for securing it about the catalytic converter.

It is generally advantageous for garages and the like to stock a limited number of replacement parts which can be utilized on more than one vehicle. Moreover, to reduce the cost of repair, it is desirable that the mechanic be able to install replacement flanges without any major disassembly of other parts, and, in the instance of exhaust system components, without having to wait for a substantial period of time for the parts to cool sufficiently so that the mechanic will not be burned when working thereabout.

It is an object of the present invention to provide a novel replacement flange for the end of catalytic converters which can be assembled quickly and easily about the converter.

It is also an object to provide such a flange which may be fabricated relatively economically from sheet metal stock.

Another object is to provide such a flange which may be installed with limited potential for contact of the mechanic's hands with hot parts of the exhaust system.

Still another object is to provide a method for quickly and easily installing such replacement flanges on vehicles.

It has now been found that the foregoing and related objects and advantages may be readily attained in a novel replacement flange for the end of a catalytic converter. This replacement flange has a pair of opposed coupling elements each having a generally vertically extending leg portion and a generally horizontally extending base portion, and the opposing edges of the coupling elements have a portion of arcuate configuration to seat a portion of the periphery of the outlet pipe of an associated catalytic converter and aligned recesses to seat the side flanges of the catalytic converter. The elements being spaced apart at the upper end of their leg portions, and each of the coupling elements has a plurality of bolt receiving apertures therein for mounting upon the support structure of the associated vehicle and for coupling to the flange of the associated exhaust system of the vehicle. A channel element seats and joins the opposed ends of the base portions of the coupling elements, and it permits horizontal sliding motion therein of one of the coupling elements relative to the other.

Preferably, the channel element is of elongated, generally U-shaped cross section defined by a pair of vertical legs and a base, and one of the legs has a groove in its inside surface extending along the length thereof. The base portion of at least one of the coupling elements has a boss thereon which slidably seats in this groove. Desirably each of the coupling elements has a boss seated in the groove, and the other one of the coupling elements and the channel element are fixedly engaged by staking or the like.

In the preferred embodiment, each of the coupling elements is of generally plate-like configuration with the boss being formed by deformation of the material from which the coupling element is formed, and the apertures for coupling to the exhaust system have internally threaded nuts thereabout to seat threadably the shanks of fasteners.

In the method of mounting the replacement flange on the end of a catalytic converter, a channel element is mounted on the base portion of one coupling element and it projects beyond the end of the base portion. The mounting the upper end of the leg portion of the coupling element is mounted upon the support structure of the vehicle with its arcuate edge extending about a portion of the outlet pipe of the catalytic converter. The other one of the coupling elements is moved horizontally to slidably seat its base portion in the channel and to seat its arcuate edge about another portion of the outlet pipe of the catalytic converter.

As a result, the channel element seats and joins the opposed ends of the base portions of the coupling elements and provides horizontal sliding motion therein of the other coupling element prior to finally securing both coupling elements to the automobile support structure. The upper end of the leg portion of the other coupling element is then mounted on the support structure of the vehicle, and the flange of the exhaust system for the vehicle is coupled to others of the apertures of the coupling elements .

Description of The Preferred Embodiment

In forming the profile of the flange portions, the walls 38 and 40 of upstanding leg 36 are spaced from each other by the top wall 42 to form a longitudinally extending cavity or corner piece receiving opening 52 for receiving the legs of angularcorner pieces which will be described later.

The outer vertical wall 38 has an inturned rebent portion generally designated by the numeral 54 that extends inwardly into the opening 52 closely adjacent the inner surface of vertical wall 40. Asillustrated in greater detail in FIG. 8, the inturned portion 54 has a tear drop configuration in side elevation with an upper leg 56 and a lower leg 58. The legs 56 and 58 extend angularly from the vertical wall 38 and form an acute angle therewith. The lower leg 58 of inturned portion 54 is spaced upwardly from and extends toward the inner surface 60 of the lower horizontal wall 46 to form therebetween a pocket generally designated by the numeral 62 as seen in FIG. 3.

Suitable gasket material 64, as illustrated in FIGS. 2 and 3, is positioned in the pocket 62 and is maintained therein by the angular relation of lower leg 58 of inturned portion 54 and the bottom horizontal wall 46 and the portion of the innersurface 39 of front wall 38 below the inturned portion 54. The gasket material 64 has a viscosity that permits the material to flow into position by application from a nozzle into the pocket 62. An example material suitable for use as the gasketmaterial 64 is a polymeric material, such as Servaseal 5511 sold by Service Adhesives, Inc. of Maywood, Ill.

Preferably the gasket material 64 remains flowable for a substantial period of time at least during the assembly of the duct joint. With this arrangement the end portion of the duct when inserted into the duct receiving leg portion 44 partiallydisplaces the gasket material within the pocket 62. The gasket material 64 sealingly connects the duct end portion to the respective flanges. Thus, an air-tight seal is formed around the adjacent metal surfaces as will be explained hereinafter ingreater detail.

The vertical rear wall 40 of the upstanding channel shaped leg portion 36 as seen in FIGS. 3 and 8 extends generally parallel to the vertical front wall 38 to a location where the inner surface of the rear wall 40 is slightly below the lower leg58 of inturned portion 54. The rear wall 40 at that location is bent to form a juncture with the top wall 48 of the duct receiving leg portion 44. The top wall 48 is inclined to and extends into abutting relation with the upper surface of the lowerwall 46 which, in turn, is bent upwardly slightly at its end portion to receive the duct end wall and frictionally engage the duct end wall between adjacent surfaces of walls 46 and 48. The above described configuration permits duct walls of differentthicknesses to be utilized and maintained in frictional engagement between the adjacent surfaces of the respective walls 46 and 48.

The vertical dimension of the pocket 62 is not critical because of the gasket material 64 positioned therein. The vertical dimension of pocket 62 may be such that it is arranged to receive duct end walls of different thicknesses and the flangeportions 28-34 may thus be utilized for joint assemblies on ducts of different wall thicknesses. It is preferred, as illustrated in FIG. 3, that the duct walls end portions be inserted into the pockets 62 and through the gasket material 64 until theedges of the duct wall end portion abut the inner surfaces 39 of the vertical walls 38. It should be understood that a seal is obtained when the edge of the duct wall end portions penetrates the gasket material 64. The gasket material 64 is operable tobe displaced and flow out of the pocket 62 at the end of the respective flanges to thereby form a seal around the end of the duct at the intersection of walls 38 and 46 adjacent corner piece 66, as illustrated in FIG. 4.

Angular corner pieces 66, as illustrated in FIGS. 1-4 and in greater detail in FIGS. 5-7 and 10 and 11, have a generally planar configuration. Each corner piece 66 has a corner section or body portion 70 and legs 72 and 74 extending angularlytherefrom in substantially the same plane as the corner section 70. The legs 72 and 74 are arranged to extend into the openings 52 of flange portions 28 and 34 while the corner section 70 remains outside of the flange portion openings 52, as illustratedin FIGS. 1-4. The corner piece 66 has a front planar surface 73 and a rear planar surface 75. The front planar surface 73 within the flange portion openings 52 is arranged to abut the inner surface 39 of the frame front wall 38. Also, as illustratedin FIGS. 5 and 6, for example, corner piece corner section 70 has a common front planar surface portion and a common rear planar surface portion with leg 72 and corner piece corner section 70 has a common front planar surface portion and a common rearplanar surface portion with leg 74. The corner piece 66 has an elongated embossed portion 76, as illustrated in FIGS. 5, 6, 10 and 11 which extends from a location adjacent the end portion 78 of the leg 72 to the corner section 70 and continues throughthe corner section 70 along the other leg to a location adjacent the end portion 80 of leg 74. The embossed portion 76 has a front concave surface 77 and a rear convex surface 79. The convex surface 79 within the flange portion openings abuts the frontsurface of the flange rear wall 40. With this arrangement, the legs 72 and 74 have a front planar surface 73 that abuts the rear surface 39 of flange front wall 38 and a convex surface 79 that abuts the inner surface of rear wall 40

The legs 72 and 74 have apertures 82 therein to permit dimpling of the frame portions after assembly of the frame member 26. The corner section 70 has a bolt aperture 84 arranged to receive a connecting bolt. The corner piece 66 has shoulders86 and 88 adjacent the upper and lower edges 90 and 92 of leg 72 and shoulders 94 and 96 adjacent the upper and lower edges 98 and 100 of leg 74, defining the boundary of the corner piece corner section 70 relative to legs 72 and 74. The shoulders 86,88, 94 and 96 serve as a stop means and operable as stops arranged to abut ends 102 and 104 of flange portions 28 and 34, as illustrated in FIG. 3 to limit the length the legs 72 and 74 extend into the flange portions 28 and 34. The corner piece cornersection 70 has a lower corner portion generally designated by the numeral 83 having an L-shaped flange or offset portion 85, as illustrated in FIGS. 7 and 10. The flange portion 85 has an arcuate or offset portion 89 which is displaced or curvedrearwardly in a direction away from the corner piece front planar surface 73 toward the rear planar surface 75. The flange arcuate portion 89, as illustrated in FIGS. 5-7, has a front surface 91, a rear surface 93, and an L-shaped end or edge portion 95which is displaced rearwardly from the front planar surface 73. The edge portion 95 extends from the shoulder 88 to the shoulder 96. The flange 85 is thus bounded by the shoulders 88 and 96 and the L-shaped edge portion 95.

With the above described arrangement of the corner piece 66, the leg portions 72 and 74 are positioned in the openings 52 of flange portions 28 and 34. The top walls 42 of the upstanding channel shaped leg portions 36 serve as a stop means andabut shoulders 86 and 94 to prevent the corner section 70 of the corner piece 66 from extending into the longitudinal openings 52. With the corner piece 66 in this position as illustrated in FIG. 8, the front surface 91 and L-shaped edge 95 of therearwardly or displaced curved flange or offset portion 85 are displaced rearwardly from the inner surface 39 of the front wall 38 and spaced above the upper surface of horizontal bottom wall 46 so as to provide clearance for the corner edge portions 22and 24 of the duct end portion to extend beyond the edge portion 95 and the surface 91 of flange portion 85 permitting the duct end portion to be positioned closely adjacent to or in abutting relation with the inner surface 39 of the flange front wall38. With this arrangement an air-tight seal is provided around the corner edge portions 22 and 24 adjacent the flanges 28 and 34 by the penetration of the duct edge portions 22 and 24 into a gasket 106, positioned on the corner piece corner section 70,as illustrated in FIG. 4 and as will be explained later in greater detail.

As illustrated in FIG. 11, the leg 72 of corner piece edges 90 and 92. When the leg 72 is positioned in the opening 52 of flange portion 28, as illustrated in FIGS. 3 and 8, the upper edge 90 of leg 72 abuts the under surface of the horizontalwall 42 and the lower edge 92 abuts upper leg 56 of the inturned portion 54. The rear convex surface 79 of the embossment 76 abuts the inner surface of the rear wall 40 while the planar front surface 73 of the leg abuts the inner surface 39 of the frontwall 38. With this arrangement, the leg 72 of the corner piece 66 abuts the surfaces of both the front wall 38 and rear wall 40 in the cavity 52 and the upper edge 90 abuts the horizontal wall 42 while the lower edge 92 abuts the surface of the inturnedportion upper leg 56. This provides a rigid, sturdy connection between the corner piece leg portion and the flange portion.

As above described, the shoulders 88 and 96 are arranged to abut the ends 102 and 104 of the flange portions 28 and 34 so that the lower corner portion 83 of the corner piece corner section 70 does not extend into the longitudinal openings 52 ofthe respective flange portions. Therefore, the rearwardly curved or displaced flange portion 85 of the corner portion 83 is in juxtaposition with the flange portion ends 102 and 104. Further, as illustrated in FIGS. 4 and 8 the front surface 91 of thearcuate flange portion 85 along the edge 95 is spaced rearwardly from the inner surface 39 of the flange portion front wall 38.

The longitudinal edge 95 also is spaced above the horizontal inner surface 60 of the flange bottom wall 46. With thisarrangement, clearance is provided between the L-shaped edge 95 of the corner piece flange portion 85 and the bottom wall upper surface 60 to permit the duct end portions to pass between the duct receiving walls 46 and 48 into abutting relation with theinner surface 39 of the flange front wall 38 and the corner edge portions 22 and 24 to pass beyond the longitudinal edge 95 and flange surface 91. With this arrangement, as illustrated in FIG. 4, the end portions of the duct 10 extend into the flangeportions of the frame member 26 with the exception of the L-shaped corner portions of the duct. The exposed portions of the duct corner edge portions 22 and 24 are not embedded in the mastic seal and it is essential that a seal be provided along theseexposed corner edge portions 22 and 24 of the duct. Thus, the plane corner edges 22 and 24 of the duct end portions extend beyond the edge portion 95 of the corner piece lower corner portion flange 85 into the surface of the gasket 106.

The frame members 26 are formed by first cutting preselected lengths of the strips having preformed flange portion profiles. For example, frame portions 28, 30, 32 and 34 are cut from a strip of the flange shaped profile. Four corner pieces 66have the leg portions 72 and 74 inserted in the openings 52 in the respective upstandng channel shaped leg portion 36 so that they extend into the openings 52 their entire length with the shoulders 86, 88, 94 and 96 abutting the edges of the respectiveflange portions. With the corner pieces 66 secured in the openings, the generally rectangular frame 26 is then secured to the end of the duct 10 by passing the duct walls 12-18 between the legs 46 and 48 of the duct receiving leg portion 44. The endportions of the respective duct walls 12-18 are urged into the flange portions 28-34 until the duct end wall portions penetrate the gasket material 64 and abut the inner surfaces 39 of the frame portion vertically extending walls 38.

It will be apparent that due to variations in the thickness of the duct end wall portions, the duct end portions may be spaced slightly from the front wall 38 but closely adjacent thereto to the extent that the edge of the duct displaces thegasket material 64 in the pocket 62. Consequently, the flowing type gasket material extrudes outwardly around the upper and lower surfaces of the duct wall portions to seal the end portion of the duct wall in the respective pocket 62 of the flangeportion.

Further, a portion of the gasket material 64 extrudes longitudinally, as illustrated in FIG. 4, beyond the ends of the flange portions adjacent the corner piece corner portion 83. The gasket material 64 flows between a respective corner pieceshoulder portion, for example shoulder 88, and the adjacent flange end portions and onto the flange portion 85. Further when the gasket material 64 is extruded from the open end of the flange it flows into the space between the upper surface of the endof the duct wall and the edge 95 of the corner piece flange portion 85. This arrangement provides an effective air-tight seal between the flange and the duct and the corner piece and the duct with the flange. For purposes of illustration only thegasket material 64 has been omitted from flange portion 34 shown in FIG. 4.

As illustrated in FIG. 9, pairs of ducts are positioned with the flange members in abutting relation with each other. A suitable relatively thin gasket member 106 such as neoprene, polyethylene or the like, is positioned between the upstandingchannel shaped leg portion front walls 38 on the outer surface 37 thereof and between the surfaces of the corner pieces 66. Preferably, the gasket member 106 is formed or shaped to meet the dimensions of the duct end wall and the respective framemembers 26. Bolts 25 are inserted through the respective apertures 84, and nuts 27 are threadedly secured to the bolts 25 to thus secure the corner pieces 66 to each other and, in turn, secure the respective frame members 26 to each other with the ducts10 secured thereto.

With this arrangement, the frame members 26 provide a joint assembly for securing the duct members 10 to each other and to form an air-tight seal therebetween. The configuration of the flange portions permits duct members having walls ofdifferent thicknesses to be utilized with the frame portions having the same dimension. The edges of the duct walls extend into the flowing type gasket material 64 in the longitudinal openings 52 to provide an air-tight seal between the undersurface ofthe duct wall and the uppersurface of the duct receiving leg portion and further around the duct end wall between the upper-surface of the duct wall and the innersurface 39 of front wall 38. In addition the flowing type gasket material 64 is effectiveto form an air-tight seal where the surfaces of duct walls or the walls of the frame portions are irregular due to the coating applied to the surface during the galvanizing operation.

Further it will be apparent from the present invention that by rearwardly curving or displacing the corner piece flange portions 85 that form the corner piece corner portion 83, the duct corner edge portions 22 and 24 are operable to extend intoor penetrate the gasket member 106 which is positioned between the upstanding channel shaped leg portions 36 in overlying relation with the corner piece lower corner portions 83. In this manner air from within the duct is prevented from flowing aroundthe duct end wall and between the upper surface of the duct and the surface of the corner piece flange edge 95.

According to the provisions of the patent statutes, I have explained the principle, preferred construction, and mode of operation of flange invention and have illustrated and described what I now consider to represent its best embodiments. However,it should be understood that, within the scope of the appended claims, the invention may be practiced otherwise then as specifically illustrated and described.

Brief Description of The Drawings and Flange

FIG. 1 is a fragmentary, exploded perspective view of a flange type duct joint assembly for connecting the end portions of a pair of ducts, illustrating a plurality of angular corner pieces for connecting adjacent flange portions to form a framefor receiving the end portions of the ducts.

FIG. 2 is an enlarged perspective view of an angular corner piece and adjacent flange portions.

FIG. 3 is a perspective view of a corner of the end of a duct with the flange portions connected thereto and the corner piece connecting the adjacent flange portions.

FIG. 4 is a fragmentary perspective view of a corner of the end portion of a duct sealingly connected to a pair of adjacent flanges connected by a corner piece, illustrating the edge of the duct extending beyond a flange portion of the cornerpiece. 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, theflange of the corner piece, and the end of the duct.

FIG. 5 is a perspective view of an angular corner piece, illustrating a rearwardly displaced or curved flange portion extending from the inner corner of the corner piece.

FIG. 6 is a perspective view of the opposite face of the angular corner piece shown in FIG. 5, illustrating the configuration of the rearwardly displaced or curved flange portion of the corner piece.

FIG. 7 is a fragmentary perspective view of a corner piece, illustrating the rearwardly displaced or curved flange portion.

FIG. 8 is a fragmentary sectional view of the end portion of the duct abutting the front wall of an upstanding channel shaped leg portion of the flange and penetrating the gasket member positioned on the flange and the corner piece, illustratingthe flange portion of the corner piece curved or displaced rearwardly from the front wall of the channel shaped leg portion.

FIG. 9 is a fragmentary sectional view of the end portions of a pair of ducts connected by the duct joint assembly of the present invention, illustrating the flanges secured to the ducts with the flanges abutting a gasket therebetween.

FIG. 10 is a sectional view of a corner piece taken along the lines X--X of FIG. 7, illustrating the configuration of a leg of the corner piece and the curved or displaced flange portion of the corner piece.

FIG. 11 is a sectional view of a corner piece taken along lines XI--XI of FIG. 7, illustrating the configuration of a corner piece.

Referring to the drawings and particularly to flange. 1-4, there is illustrated the end potion of a pair of duct sections generally designated by the numeral 10 in which each duct 10 has a generally rectangular configuration with an upper duct wall12, a lower duct wall 14, and a pair of vertical duct sidewalls 16 and 18. The ducts 10 are formed in the rectangular configuration illustrated in flange. 1 with a longitudinally extending sealed corner joint 20 between the lower duct wall 14 and thesidewall 16.

As illustrated in flange. 3, the duct upper wall 12 and the duct sidewall 18 terminates in end portions having corner portions with corner edge portions 22 and 24. It should be understood, although not shown, that the other duct walls 14 and 16terminate in similar end portions so that the end portions of the duct 10 extend along a plane transverse to the longitudinal axis of the duct 10.

Each of the ducts 10 preferably is fabricated from galvanized sheet material and may have various thicknesses. For example, commercial grade 20 gauge duct has a thickness of between 0.906 and 1.106 millimeters. The galvanized surface of theduct walls also provides a relatively irregular surface so that the thickness of the sheet metal forming the duct 10 is not uniform along the duct end portions.

The end portions of the pair of ducts 10 are secured to each other by a pair of frame members generally designated by the numeral 26. The frame members 26 are similar in construction and are secured to the ends of adjacent duct sections and areconnected to each other by bolts 25 and nuts 27, shown in FIG. 1 as will be described later in greater detail. Each frame 26 is formed by a plurality of duct connecting flanges that extend outwardly from the duct wall end portion and include an upperflange portion 28, a lower flange portion 30 and a pair of side flange portions 32 and 34. The configuration of the flange portions 28-34 are identical and are preferably cut to a preselected length from an elongated sheet metal strip that has been rollformed into the flange configuration illustrated in the drawings. Throughout the specification, the flange portions 28 and 34 and the connections therebetween will be described in detail; however, it should be understood that the other flange portionsare similarly connected to the duct end portions and to each other.

The flange portion 28 is illustrated in detail in FIGS. 2, 3, 4, 8 and 9. The flange 28 has an upstanding channel shaped corner piece receiving leg portion or upstanding corner piece receiving portion generally designated by the numeral 36 witha front wall 38 connected to a rear wall 40 by a generally horizontal top wall 42. A shoulder 43 is formed between the walls 40 and 42 and is adapted to receive a longitudinal clip 41 illustrated in FIG. 9. Extending laterally at substantially a rightangle from the upstanding channel shaped leg portion 36 is a duct receiving leg portion or duct receiving portion generally designated by the numeral 44 which has a bottom wall 46 and a top wall 48. The top wall 48 has an upturned lip portion 50 topermit the end wall of the duct to slide between the respective walls 46 and 48 so that the duct end wall is frictionally engaged between adjacent surfaces of the flange walls 46 and 48.

Summary of The Flange Portions Invention

In accordance with the present invention there is provided a flange type duct joint assembly to connect the end portions of generally rectangular ducts or duct sections that includes a plurality of flange portions or duct connecting flanges.

Aplurality of angular corner pieces are provided for connecting adjacent flange portions to form a generally rectangular frame. The flange portions each have an upstanding channel shaped leg portion or upstanding corner piece receiving portion and a ductreceiving leg portion or duct receivng portion. The upstanding channel shaped leg portion includes a front wall and a rear wall forming a corner piece receiving opening therebetween. The duct receiving leg portion includes a top wall and a bottom wallarranged to receive an end portion of a duct therebetween.

The upstanding channel shaped leg portion front wall intersects the duct receiving leg bottom wall. The corner pieces each have a body portion or corner section and a pair of legs extendingangularly therefrom. The corner piece corner section and the legs have a common front planar surface portion and a common rear planar surface portion. The pair of legs are arranged to extend into the corner piece receiving openings of the flangeportion upstanding channel shaped leg portions.

The corner piece body portion includes a corner portion having a flange portion or offset corner portion extending from the body portion. The corner section flange portion is in juxtaposition with theupstanding channel shaped leg portion where the front wall of the upstanding channel shaped leg portion intersects the bottom wall of the duct receiving leg portion. The corner section flange portion has a front surface and a rear surface.

The flange portion front surface is displaced from the inner surface of the front wall of the upstanding channel shaped leg portion. The corner piece offset corner portion is positioned externally of the corner piece receiving openings in the adjacent ductconnecting flange upstanding corner piece receiving portions. The corner piece corner section offset corner portion is displaced rearwardly relative to the corner piece front planar surface and above the duct connecting flange duct receiving portionbottom wall.

The duct receiving leg portion is adapted to receive the duct end portion so that the corner edge portions of the duct end portions extends or projects beyond the corner piece offset corner portion into abutting relation with an externalgasket means positioned on the corner piece corner section to provide a seal for the duct corner edge portion between adjacent duct connecting flange portions. The external gasket means is positioned in overlying relation with the duct connecting flangefront wall and a portion of the corner piece corner section.

A deformable gasket, such as a flowing type gasket material, is positioned inside the flange portions and is operable to sealingly connect the duct end portion within the flange portions. The deformable gasket abuts the channel shaped legportion front wall and the duct receiving leg portion bottom wall. The deformable gasket means is partially displaced inside the channel shaped leg portion and duct receiving leg portion when the duct end portion is inserted into the duct receiving legportion. With this arrangement, the gasket material is operable to flow into sealing relation around the edge of the duct end portion in the duct receiving leg portion.

Preferably, the deformable gasket is partially displaced inside the channel shaped leg portion and the duct receiving leg portion when the duct end portion is inserted into the duct receiving leg portion to permit the edge of the duct end portionto move into abutting relation with the front wall of the channel shaped leg portion. The deformable gasket material has a viscosity that permits the material when displaced by movement of the duct end portion into the duct receiving leg portion toextrude out of the respective flange portions and onto the surface of the edge of the duct adjacent to the corner piece and onto the surface of the corner piece to provide an air-tight seal between the end of the duct adjacent the corner piece and thecorner piece at the ends of the flange portions.

Further, in accordance with the present invention an external gasket is positioned in overlying relation with the outer surface of the upstanding channel shaped leg portion front wall and the surface of the body of the corner section of thecorner piece. The external gasket is penetrated by the corner edge portions of the duct end portion. The duct corner edge portions extend beyond the front surface of the corner piece flange portion to provide a seal between the outer surface of theduct edge and the front surface of the corner piece flange portion to prevent the flow of air therebetween.

Further, in accordance with the present invention the front wall of the upstanding channel shaped member has an inner surface arranged to receive in abutting relation the edge of the duct end portion. The outer surface of the corner piece flangeportion is preferably curved or displaced rearwardly away from the front wall inner surface. With this arrangement the duct end portion is permitted to extend beyond the corner piece flange portion so that the duct edge can penetrate an external gasketpositioned on the surface of the flange portions and corner pieces. This arrangement provides an effective corner seal for the duct joint assembly.

Another feature of the present invention is to provide a corner piece for connecting end portions of duct connecting flanges. The corner piece includes a corner section with a rearwardly displaced flange portion. The rearwardly displaced flangeportion is arranged to permit the duct corner end portions to project into abutting relation with an external gasket and seal the corner edge portions of the duct.

Another feature of the present invention includes a flange type duct joint assembly for connecting the end portions of generally rectangular ducts or duct sections which assembly includes a plurality of flange portions or duct connecting flanges. A plurality of angular corner pieces are provided for connecting adjacent flange portions to form a generally rectangular frame.

The flange portions each have an upstanding channel shaped leg portion or upstanding corner piece receiving portion and aduct receiving portion or a duct receiving leg portion. The upstanding channel shaped leg portion includes a front wall and a rear wall forming a corner piece receiving opening therebetween. The duct receiving leg portion includes a top wall and abottom wall arranged to receive an end portion of a duct therebetween. The upstanding channel shaped leg portion front wall intersects the duct receiving leg bottom wall.

The corner pieces each have a body portion or corner section and a pair of legsextending angularly therefrom. The corner piece corner section and the legs have a common front planar surface portion and a common rear planar surface portion. The pair of legs are arranged to extend into the corner piece receiving openings of theflange portion upstanding channel shaped leg portions. The corner piece body portion has a corner portion with a flange portion. The flange portion has an edge or edge portion. The flange portion edge is displaced from the upstanding channel shapedleg portion to permit the edge of the duct end portion to be positioned closely adjacent to the intersection of the upstanding channel shaped leg portion front wall and the duct receiving leg bottom wall.

The corner piece flange portion is positionedexternally of the corner piece receiving opening in the adjacent duct connecting flange upstanding corner piece receiving portion. The corner piece flange edge portion is displaced rearwardly relative to the corner piece front planar surface and abovethe duct connecting flange duct receiving portion bottom wall so that the duct section corner edge portion, between adjacent duct connecting flange portions, projects beyond the flange edge portion into abutting relation with an external gasket meanspositioned on the corner piece corner section to provide a seal for the duct corner edge portion between adjacent duct connecting flange portions.

The external gasket means is positioned in overlying relation with the duct connecting flange front walland a portion of the corner piece corner section. This sealing device or external gasket means is provided for maintaining an air-tight seal between the outer surface of the duct open end portion adjacent the corner piece and the edge of the cornerpiece flange portion so that the corner pieces of the generally rectangular frame sealingly engage the duct end portion to prevent air from within the duct flowing between the upper surface of the duct and the flange portion edges of the corner pieces.

Accordingly, the principal object of the present invention is to provide a flange type duct joint assembly to connect the end portions of generally rectangular ducts and a plurality of flange portions that are connected to adjacent flangeportions by angular corner pieces that are arranged to receive an end portion of a duct and provide an air-tight seal between the corner edge portions of the duct end portion and the surface of the corner piece.

Another object of the present invention is to provide a seal arrangement between the end portion of a duct and angular corner pieces that connect a plurality of flange portions that form a frame for receiving the duct end portion to prevent flowof air from the duct between the duct end portion and the corner pieces of the frame.

A further object of this invention is to provide a corner piece that permits the duct corner edge portions to project into sealing relation with an external gasket.

An additional object of this invention is to provide a flange type duct joint assembly to connect end portions of generally rectangular duct sections that permits the duct section corner edge portions to project into sealing relation with anexternal gasket.

These and other objects of the present flange invention will be more completely disclosed and described in the following specification, the accompanying drawings, and the appended claims.

Background of The Flange Portions Invention

1. Field of the Invention

This invention relates to a joint assembly for sealingly connecting the ends of a pair of sheet metal duct sections and more particularly to a joint assembly that includes a pair of frame members having flange portions secured to each other byangular corner pieces having rearwardly curved or displaced flange portions operable to facilitate an air-tight seal between the ends of the duct sections and the frame members.

2. Description of the Prior Art

U.S. Pat. No. 3,712,650 discloses a flange connection for connecting the ends of rectangular air conditioning ducts that includes flange portions each having a horizontal leg portion secured to the end portion of the duct and a vertical channelshaped leg for receiving the arm of an angular corner piece. A wall of the horizontal flange portion has a sloping intermediate portion that permits visual access to the bend areas between the adjacent walls of the duct and the ends of the duct walls.

The angular corner pieces have arm portions which each extend into an opening in the vertical channel shaped flange. The arm portions are so dimensioned vertically that the lower surface of each arm abuts the lower wall of the horizontal flange. With this arrangement the end of the duct wall abuts or rests against the surface of the corner piece arm extending into the channel shaped opening.

Another joint assembly for connecting the ends of a pair of ducts is disclosed in German application No. P 25 56 167 filed Dec. 13, 1975, and includes a plurality of flange portions secured to the ends of the ducts and angular corner piecespositioned in vertically extending channel shaped openings in the respective flange portions to form a generally rectangular frame secured to the ends of the ducts.

The flange portions each have a generally horizontal duct receiving leg and a verticalchannel shaped leg. The duct receiving leg portion has a longitudinal opening for receiving the duct end wall and one wall of the vertically extending channel shaped leg has an inturned or inwardly rebent portion that forms a longitudinally extendinglip spaced from the lower wall of the horizontal duct receiving leg.

The duct end portion is arranged to extend into the space between the longitudinally extending lip and the lower wall of the horizontal duct receiving leg. In position, the duct endwall abuts the inner surface of the outer vertical wall of the upstanding channel shaped leg. The arm of the corner piece is arranged to extend into the opening above the inturned lip so that the corner piece arm portion is spaced from the duct end wallby the inturned lip portion. The corner pieces have arms with a curved configuration so that pairs of facing arms in adjacent frames are intended to exert a joinder pressure on the respective frame when the corner pieces are bolted to each other.

In the above joint assemblies, the duct end walls abut either the arm of the corner pieces or abut the inner surface of the frame channel shaped leg portion outer vertical wall. Where the end of the duct wall rests against the arm of the cornersection, a space is provided between a substantial portion of the outer vertical wall of the channel shaped leg and the end of the duct wall. Where the end of the duct wall is positioned in the space between the inturned lip and the horizontal bottomwall, the duct end wall abuts a portion of the vertical wall of the frame section between the lip and the horizontal bottom wall. In either instance, irregularities on the surface of the duct or on the surface of the frame portions permit leakage of airfrom the duct through the flange connection. Positioning gasket material on the outer surface of the frame portions does not eliminate this air leakage since the leakage is occurring within the frame portions and around the duct end wall.

In German Offenlegungschrift No. 2,221,312 published Nov. 15, 1973, a fibrous gasket material is disclosed as positioned between the upper surface of the duct end portion and the under surface of the inturned rebent portion. French Pat. No.1,363,255 discloses two pieces of sheet metal joined by a fold arrangement with a sealant engaged to the edge of one of the metal sheets. U.S. Pat. No. 3,246,918 discloses a flange connection in which sealing is achieved by the penetration of an endof a duct into a mastic.

One problem encountered with the joint assemblies of the prior art is the inability to form an air-tight seal around the duct end wall positioned oppositely of the vertical wall of the frame section adjacent the horizontal bottom wall of theframe section.

One proposed solution to this problem, as disclosed in the German OLS, referred to above, is positioning a longitudinally extending gasket in the longitudinal space between the inturned rebent portion and the lower wall of the horizontal ductreceiving leg. If, when the duct end wall is inserted in the duct receiving leg portion, the gasket material is rolled up against the inner surface of the vertical wall of the channel shaped leg portion, an incomplete seal is formed around the end ofthe duct and the inner surface of the bottom wall of the duct receiving leg portion.

Consequently, the end of the duct is substantially spaced from the inner vertical wall of the channel shaped leg portion. An air space is thus formed between theoutside gasket on the outer surface of the frame portions and the duct edge because the outside gasket rests on the corner pieces and does not contact the duct edge. This permits air from the duct to flow around the end of the duct and between theoutside surface of the duct and the under surface of the corner piece. Thus, air leaks from the ducts at the corners of the frame connecting the ducts.

There is need for a joint assembly that provides an effective corner seal between the duct end wall and the corner pieces that connect the adjacent flanges that form the joint frame. While it has been suggested by the prior art joint assembliesto utilize a longitudinally extending gasket in the flange portions to form a seal around the duct end portion in the flange portions, the gasket inside the flange portions does not prevent leakage around the corner pieces adjacent the ends of the flange portions.

In addition, even with the use of an outside gasket on the corner pieces, unless the edge of the duct abuts the inner surface of the vertical wall of the flange portion, the outside gasket does not contact the end of the duct and air will leakaround the end of the duct and between the duct and the corner piece beneath the outside gasket.

Flange type duct joint assembly and seal arrangement therefor

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 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 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 corner 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.

Claims

I claim:

1. A corner piece for connecting a pair of duct connecting flange members comprising,a corner section with a pair of legs extending angularly therefrom,said corner section and said legs having a common front planar surface portion and a common rear planar surface portion,said legs arranged to extend into said duct connecting flange members to form a generally rectangular duct frame for connection to a duct end portion,said corner section having an offset corner portion displaced rearwardly from said common front planar surface portion, and said corner section offset corner portion and said corner section front planar surface being operable to permit a corner edge portion of the duct end portion positioned between the end portions of adjacent duct connecting flange members toproject beyond said offset corner portion into abutting relation with an external gasket means and said corner section front planar surface in abutting relation with said gasket to seal the corner edge portion of the duct.

2. A corner piece for connecting a pair of duct connecting flange members as set forth in claim 1 in which,said offset corner portion has a generally L-shaped configuration with opposite end portions, and said offset corner portion arranged to be spaced above a duct connecting flange duct receiving portion bottom wall.

3. A corner piece for connecting a pair of duct connecting flange members as set forth in claim 1 in which,said offset corner portion has a generally L-shaped configuration defined by a front surface and a rear surface forming an edge portion therebetween, and said offset corner portion edge portion positioned rearwardly of said common front planar surface portion.

4. A corner piece for connecting a pair of duct connecting flange members comprising,a corner section with a pair of legs extending angularly therefrom,said corner section and said legs having a common front planar surface portion and a common rear planar surface portion,said corner section having a corner portion,a flange portion extending from said corner section corner portion, said flange portion having an end portion displaced rearwardly from said common front planar surface portion, and said corner section front planar surface and said flange portion end portion being operable to permit a corner edge portion of a duct end portion positioned between the end portions of adjacent duct connecting flange members to project beyondsaid flange end portion into abutting relation with an external gasket means and said corner section front planar surface in abutting relation with said gasket means to seal the corner edge portion of the duct.

5. A corner piece for connecting a pair of duct connecting flange members as set forth in claim 4 in which,said flange portion has a generally L-shaped configuration with opposite end portions, and said flange portion end portion arranged to be spaced above a duct connecting flange receiving portion bottom wall.

6. A corner piece for connecting a pair of duct connecting flange members comprising,a corner section having a front surface,a pair of legs extending angularly from said corner section,said corner section having a corner portion with a flange portion having an L-shaped edge portion,said flange portion having a front sealing surface arranged to abut an external gasket means to seal the corner portion of the duct, and said flange portion L-shaped edge portion being offset at an angle less than 90° from said corner section front surface so that said L-shaped edge extends rearwardly in a direction from said corner section front surface to said cornersection rear surface.

7. A corner piece for connecting a pair of duct connecting flange members as set forth in claim 6 in which,said flange portion offset L-shaped edge extends along a curved path rearwardly from said corner section front surface.

8. A corner piece for connecting a pair of duct connecting flange members as set forth in claim 6 in which,said pair of legs each has a front surface and a rear surface,said corner section front surface and said legs front surfaces having portions positioned in a common plane to form a common front planar surface, and said corner section rear surface and said legs rear surfaces having portions positioned in a common plane to form a common rear planar surface.

9. A corner piece for connecting a pair of duct connecting flange members as set forth in claim 8 in which,said flange portion offset L-shaped edge is displaced rearwardly from said common front planar surface.

Method of Manufacturing Closure Flanges II

The bonding of the flange 1 to a plastic container wall section, such as a pail head as indicated at 14, is accomplished by inserting the neck of the flange up through the container wall opening 15 which just fits over the enlarged neck pilotportion 7. In FIG. 5 the undersurface of the container wall, prior to bonding, rests on top of the bonding element 13 and just above the ribs 11 and 12.

Induction welding of the flange to the surrounding container wall section commences upon theapplication of a vertical force to the assembly and introduction within the magnetic field of a high frequency induction heating generator. As the thermoplastic resin of the element 13 starts to melt, together with the walls of the groove 10, the ribs11 and 12 also melt, causing the upper surface 9 of the collar 8 and the undersurface of the wall 14 to come together. The rib 12 being further removed from the bonding element 13 tends to melt more slowly, thus forming a dam against the outward flow ofbonding material. As seen in FIG. 6, the result is a permanent homogeneous bonding at the flange container wall interface. It should be noted that the groove and cooperating ribs could also be formed on the undersurface of the flange collar to enablebonding of the flange to the exterior surface of a container wall such as would be required on blow-molded containers.

The bonded flange may then be fitted with a closure plug 16 having a threaded side wall 17 terminating at its upper end in a circumferentially enlarged head 18 designed for gasketing engagement with the flange bead 5. Further protection againstleakage and pilfering can be had by crimping a tamperproof capseal (not shown) about the flange bead 5.

Considering the method herein disclosed for applying the bonding element to the flange, attention is directed to FIG. 7 which shows an applying head 20 mounted on a vertically moveable shaft 21. The head 20 consists of an inverted cup-shapedhousing 22 having a base wall 23 and a depending cylindrical wall 24 terminating in a lowermost locating surface 25. A passage 24a, as clearly seen in FIG. 8, extends angularly through the wall 24 so as to communicate with the housing interior.

The base 23 is formed with a large central opening 26 surrounded by three smaller holes 27. A cutter 28 is nested within the housing 22 having a base wall 29 surrounded by a depending cylindrical wall 30 terminating at its lower end in a shearing edge 31. The shaft 21 is slideably received through the center opening 26 in the housing member base 23 and is secured to the cutter base 29 by nut 32. A cylindrical plunger 33 is slideably mounted within the cutter 28 and has an outwardly opening groove 34formed in its exterior surface. Three screws 35 extend through the holes 27 in the housing base 23 and are secured to the plunger 33. A coiled compression spring 36 surrounds each of the screws 35 so as to resiliently urge cutter 30 and plunger 33apart.

In operation a flange 1 is seated on an anvil 37 positioned beneath the applying head 20. An elongated strand of electromagnetic bonding material 13 is fed into the passage 24a in the housing sidewall 24 and, as seen in FIG. 8, is guided by thegroove 34 around the plunger 33 into an annular form. The head 20 is then lowered down over the flange with the locating surface 25 resting against the upper surface 9 of the flange collar, and with the plunger 33 resting on top of the flange bead 5. Continued downward movement of the shaft 21 overcomes the compression of springs 36 and urges the cutter 28 downwardly relative to the housing and plunger. In so doing the shearing edge 31 is lowered over the passage 24a and severs the strand 13 alongthe interior surface of the housing wall.

As the my 28 continues to move downwardly, it pushes the element 13 ahead of it, forcing the element between the annular upstanding ribs 11 on the flange collar. The final downward movement of the cutter 28 firmly seats the element 13 within theflange groove 10 whereupon the head 20 is retracted upwardly and the parts thereof restored to their initial position. It should be noted that during the downward urging of the element 13 by the cutter 28, the leading cut end 13a and the trailing cutend 13b are lined up in a common axially extending plane as seen in FIG. 10. As a result the strand of electromagnetic bonding material is formed into a complete uninterrupted annulus with the angled surfaces 13a and 13b preventing a detrimentalradially extending gap from occurring at the joint due to minor variations in the strand length.

From the foregoing it is seen how a container closure flange molded of synthetic resin can be very simply assembled with an electromagnetic bonding element for thermoplastic induction bonding to a container openings. The assembly operationdisclosed, while lending itself very well to an automatic or semiautomatic production operation, also contributes to the quality and effectiveness of the bond between the flange and the container wall.

Method of Manufacturing Closure Flanges I

A closure flange molded of synthetic plastic resin has an internally threaded cylindrical neck surrounded at one end by a circumferentially enlarged base. An annular groove is formed on the flange base for retention of a thermoplastic bonding element having electromagnetic conducting particles embedded therein. The flange manufacture includes making the bonding element up from an elongated strand into a complete annulus and securely inserting the annular bonding element within the groove in the flange base.

Claims

Having described my invention, what I claim is as follows:

1. A method of manufacturing closure flanges for electromagnetic bonding to containers comprising the steps of molding an annularclosure flange of thermoplastic synthetic resin, supporting said flange in concentric alignment with an applying head, feeding an elongated strand of electromagnetic bonding material into said head to form an annulus displacing said head and flangetoward each other, cutting said strand into a predetermined length and applying said strand as a complete annulus to said flange as said annulus is discharged from said head.

2. A method of manufacturing closure flanges as in claim 1 and said cutting of said strand within said head forming a lap joint at the strand ends.

3. A method of manufacturing closure flanges as in claim 1 and positively locking said strand onto said flange.

Description

In the manufacture of plastic pails and drums it has been proposed to provide a closure receiving neck thereon by permanently bonding an internally threaded closure flange about a flat opening molded within the container wall. One advantageouslyemployed bonding technique consists of interposing an electromagnetic bonding element at the flange container wall interface. The bonding element is energized by placing the closure assembly within a high frequency magnetic field, causing a melt zoneand resultant bonding at the flange container wall interface.

Heretofore a number of difficulties presented themselves in attempts to refine the above described bonding technique into an efficient container fabricating operation. One such difficulty concerns the need for a production oriented applicationof the bonding element to the groove in the flange base as opposed to a strictly manual operation. Another problem concerns the need for effectively forming a strand of electromagnetic bonding material into a complete and continuous annulus. Any spacegap created at the intended juncture of the severed strand ends may introduce the likelihood of failure in bonding. Once the strand is properly applied to the flange base, the problem arises of securely retaining the bonding element within the flangebase groove during subsequent shipping and handling conditions.

SUMMARY

The closure flange assembly and method of manufacture disclosed by the instant invention advantageously overcomes the above mentioned problems through the formation of a novel groove configuration in the flange base which precludes accidentaldislodgment of the bonding element under the severest handling conditions. The method of manufacture herein disclosed includes feeding the bonding element as an elongated strand into a circular die cavity whereupon closing of the die severs the strandand inserts it as a complete annulus into the flange base groove.

It is, accordingly, a principal object of the invention to provide a new plastic closure assembly for thermoplastic bonding to a plastic container wall opening.

Another object is to provide a method of applying an electromagnetic bonding element to a closure flange to facilitate bonding to a container wall opening through the use of electromagnetic induction.

Still another object is to form an electromagnetic bonding element from an elongated strand into a complete annulus and apply the element to a closure flange so as to be securely retained thereon.

Other and more detailed objects will in part be obvious and in part be pointed out as the description of the invention taken in conjunction with the accompanying drawing proceeds.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a part elevational, part sectional view of the closure flange of the invention;

FIG. 2 is an enlarged fragmentary sectional view showing the initial position of the bonding element as it is applied to the flange base;

FIG. 3 is a sectional view similar to FIG. 3 but showing the bonding element fully seated in the flange base;

FIG. 4 is an enlarged fragmentary top plan view of the flange base with the bonding element applied;

FIG. 5 is a fragmentary sectional view showing the flange in position for bonding within a container wall opening;

FIG. 6 is a sectional view similar to FIG. 4 but showing the completed bond and a closure plug in place;

FIG. 7 is an exploded sectional view of the mechanism for applying the bonding element to the flange base in accordance with the method steps of the invention;

FIG. 8 is a view taken on line 8--8 of FIG. 7 and looking in the direction of the arrows;

FIG. 9 is an enlarged fragmentary sectional view similar to FIG. 8 showing an advanced position of the strand of bonding material within the applying mechanism; and

FIG. 10 is a sectional view similar to FIG. 9 showing a further advanced position with the strand severed and formed into a complete annulus.

As seen in FIGS. 1-6, the closure flange 1 is molded of a thermoplastic synthetic resin such aspolyethylene and consists of an upstanding cylindrical neck 2 having an interior screw thread 3. The upper end of the flange neck has a short unthreaded portion 4 and terminates in a circumferentially enlarged bead 5. The exterior surface of the flangeneck 2 has a short section 6 of reduced diameter beneath the bead 5 and is then circumferentially thickened into a lower pilot portion as indicated at 7. An annular collar 8 surrounds the base of the flange neck having an upper surface 9. An annular,upwardly opening, groove 10 is formed in the upper surface 9 spaced radially outwardly from the thickened pilot portion 7 of the flange neck. The mouth of the groove 10 is partially closed off by a pair of annular ribs 11, one at each side of the grooveand extending above the flange upper surface 9. An additional annular rib 12, extending above the upper surface 9, is formed at the outer edge of the collar 8.

The final step in the flange manufacture involves the application of an electromagnetic bonding element 13 to the flange collar for the purpose of forming a thermoplastic bond to a container wall opening. The bonding element here employed ismade up from an elongated strand of thermoplastic material, circular in cross-section and having minute metal electromagnetic conducting particles embedded therein.

The strand is formed into an annulus having overlapping end surfaces 13a and 13b whichform a lap joint and insure against the presence of any radial gap in the bonding zone. As clearly see in FIGS. 2 and 3, the cross-sectional diameter of the bonding element 13 is substantially equal to the width of the groove 10 and slightly greaterthan the closest distance between the ribs 11.

A downwardly directed force applied to the bonding element 13 causes the flexible ribs 11 to open up, allowing the element to enter the groove 10. Subsequent relaxation of the ribs after the element isfully seated within the groove serves to positively retain the element securely in place. The mechanical grip applied by the ribs 11 prevents accidental dislodgment of the element 13 during packing, shipping and handling of the finished flange.

Expertise to introduce flange

Billet of metal (excluding plate) the imposition of external force to produce plastic deformation, changes in size, shape and improve the performance, for the manufacture of machine parts, flange, workpieces, tools or methods of forming the rough.

The type and characteristics of forging

When the temperature is over 300-400 ℃ (steel blue brittle region), to 700-800 ℃, the deformation resistance will be reduced dramatically, the deformation can also be significantly improved. In accordance with the temperature in different regions of the forging, forgings for the quality and the different forging process can be divided into cold forging, warm forging, hot forging three molding temperature region. This temperature region was divided into no hard and fast boundaries, generally speaking, in the recrystallization temperature region is called forging hot forging, non-heating of the forging at room temperature is called cold forging.

Forging at low temperatures, the forging of a very small size changes. The following forging at 700 ℃, the formation of small oxide and surface decarburization phenomenon no. Therefore, as long as the deformation can be in the range of forming, cold forging easy access to good dimensional accuracy and surface finish. As long as the temperature control of cooling and lubrication, 700 ℃ temperature and forging the following can also get very good accuracy. Hot forging, as a result of deformation energy and deformation resistance are very small, complex shapes can be forged large forgings. To obtain high dimensional accuracy of forgings, 900-1000 ℃ temperature in hot forging process with the region. In addition, attention should be paid to improving the working environment of hot forging. Forging die life (forging 2-5 1000,10000 Warm Forging 1-2, 2-5 cold forging 10,000) and other temperature domain is relatively short compared to the forging, but it's freedom, and low cost.

Blank in the cold forging to produce deformation and work hardening, so that forging die under high load, therefore, need to use high-intensity use of the forging die and bonded to prevent wear and lubricating film rigid approach.

In addition, to prevent the billet crack, intermediate annealing necessary to ensure that the needs of the deformation capacity. In order to maintain good lubrication can be carried out on the blank phosphate processing. The use of bar and wire rod for continuous processing, the current cross-section also can not be dealt with lubrication, lubrication is studying methods of use of the possibility of phosphide.

Identify the method of fake and shoddy steel

Prone to collapse and shoddy steel. Fold is formed on the surface of a variety of steel flange line, which runs through the entire product defects are often vertical. Have folded because of shoddy manufacturers high efficiency, large reduction, resulting in sub-ears, rolling on the next have folded, folded products will crack after bending, the strength of steel fell.

Frequent appearance of inferior steel surface phenomenon Ma. Ma rolling groove surface wear due to serious anomalies arising from the uneven surface of steel deficiencies. Inferior to steel manufacturers as a result of the pursuit of profit, often rolling over the rolling groove.

Easy to produce inferior steel surface scarring. There are two reasons: 1. Inhomogeneous materials and shoddy steel products, and more impurities. 2. Materials and shoddy equipment manufacturers guide simple, easy to stick steel, these impurities after roll bite scar easily.

Inferior surface cracks easily because it is the blank adobe, adobe porosity, and adobe in the process of cooling due to the role of thermal stress, resulting in cracks, the crack there after rolling.

Inferior steel scratches easily, because the poorly equipped and inferior materials manufacturers, easy to produce burr, scratch the surface of steel. Depth of scratches reduced the strength of steel.

Non-metallic luster and shoddy steel, cast iron or similar red color, due to 2.2, which is adobe blank. 2, inferior materials rolling temperature non-standard, their steel temperature is visual, so that can not be required to carry out rolling of the austenite region, the properties of steel can not be achieved naturally.

Transverse steel reinforcement and inferior thin and low, are often dissatisfied with the phenomenon of charge, because the big manufacturers to achieve a negative tolerance, finished before the reduction of several large, iron-type small, hole filling dissatisfaction.

Inferior surface of steel oval-shaped cross section, the reasons for the factory owners in order to save materials and finished products of the two pre-roll reduction too, the strength of steel decreased significantly, but does not conform to the standard size rebar.

Uniform composition of high-quality steel, cold high tonnage shear, cut the first face smooth and tidy, and the material as a result of poor materials and shoddy, often there will be cut off the first face of the phenomenon of meat, that is rugged and non-metallic luster. Manufacturers as a result of inferior materials and cut the first few products, end to end will be a great handle.

Inferior steel material containing impurities, and the density of small steel and super-size difference a serious problem, the vernier caliper in the absence of circumstances, it can be weighed to check it. For example, the rebar 20, the national standards set forth in the most negative tolerance of 5% of its length when 9M single theoretical weight of 120 kilograms, its minimum weight should be: 120 X (l-5%) = 114 kilograms , weighing out the actual weight of a single 114 kilograms more than the small, it is inferior steel, because it exceeds the tolerance of negative 5%. Generally commensurate with the volume of the whole will be better, mainly taking into account the accumulated error and the probability of the problem.

Size of the diameter of inferior steel volatile because; l, there are yin and yang steel surface temperature instability. 2, non-uniform composition of steel. 3, due to inadequate facilities, ground-based low-intensity, large bouncing mill. There will be changes in the same week a larger diameter, so that even the reinforced fracture easily.

High-quality printing materials are trademarks and fairly standard.

Three steel diameter of more than 16 threads, the distance between the two trade marks are more than IM.

And inferior longitudinal steel rebar reinforcement often wavy.

The absence of inferior steel flange manufacturers lane, so relatively loosely packed. Oval-shaped side.

MXR M 117R Flanger Pedal for Guitar

If you have been considering buying some effects flange pedals for your guitar, it is likely that you're looking in the wrong places if you are not check out what MXR has to offer. The company makes the best sounding, most well bit, least size consuming pedals on the market and I could not be more pleased with their products. Nearly every single pedal that I have tried sounds top notch. In comparison to competing pedal makers, MXR makes the same products in half the size and they sound twice as good.

The MXR M 117T Flanger Pedal for Guitar is one that you will want the moment you try it out. If you are after a flange pedal, I would say that you can just buy this one on the internet without even trying it out. The pedal's analog modeling offers a tone that is as pure as heaven. Manual, Width, Speed and Regen allow you to interact with playful tones dedicated to expanding the shores of your guitar wash.

You can control the waves with Width. You can make them extremely long and exaggerated or short and punchy. Speed will increase or decrease the velocity at which each wave passes. Regen will act as the effect intensity control. Manual provides a balance for the effect on your signal. Use this to create the ideal mix of flanged wetness with bare dryness.

I think what you will notice about this pedal is that it is silent. So many flange units can cause a hissing noise from you amplifier. In that hissing noise, you will actually hear the wavering flange. For extremely soft parts in dynamic changes, you cannot have a device that does this. It blows your cover. It negates from the work you put in to playing quietly and cautiously.

So many companies are producing effects pedals that are just over the top. When you have devices that have 50 different capabilities and features, it can be great. One thing to pay close attention to, however, is the integrity of each individual effect. There is a special craft in making a pedal sound as good as it can possibly sound. There is merit in having a pedal with crazy capabilities but it should not outweigh the fact that the effects need to resound with conviction. MXR is creating some of the coolest effects on the market and I continue to be amazed at how much clearer they sound than others that make the same bold promises.

Rather than being solely digitized and having a setting that is supposed to sound like analog, MXR takes the high road. Most of their pedals are constructed in full analog for the purest tone possible. It may seem like this is not a big deal. The difference is immense. Picture the difference in quality between a solid state peavey head and a Sunn Model T tube head. The same proportion applies in the balance between digital and analog pedals. Some people might not care. Though once you understand the magnitude of analog effects, you will never be able to have complacence in most digital versions.

The MXR Micro Flanger is a powerful pedal and more compact that any others like it. Due to the awesome, intelligent design, this tiny pedal can fit in any space on your board and provide earthy tones to liven up any part of your songs. The pedal has two knobs for Rate and Regen. Rate will allow you to designate a speed for your flange waves to reappear. Regen will handle the intensity of the effect on your signal.

This pedal has the standard single input and output on either side. It can be powered by an adapter to avoid spending a fortune on 9 volt batteries. The pedal has an LED indicator light to keep you aware of the position the pedal is in. With true bypass, your rig will never lose an ounce of juice because it is impossible for this pedal to detract from it.

A brilliantly tiny, wonderfully affordable, shimmering example of what pedals these days should be trying to replicate!

At $170, it may seem like a pricey investment. Compared to a lot of other flange, this actually is a little steep. I advise you checking on Harmony Central and finding other user reviews. So many folks are boasting about their MXR flanger exceeding ten years of age and still running with strength!

Home Tips: Windows that Don't Feel Cold

Most windows that you buy today have a nailing flange that goes all the way around the window. This allows for easy installation with little to no need for extra caulking flashing or other such extra steps. In other words, installing windows properly is easy. However, you may notice that there is a great deal of trim on the inside of your windows and they always feel drafty and there always seems to be condensation in the winter time. Why is that?

Draft

The air movement you feel in front of your windows usually is not air moving through them if they are newer. That air movement is what is referred to as the "convective loop". This loop is the product of the cold temperature outside convecting through the glass and meeting the warm air of the house. This is the same way wind is formed. Warm air from the ground rises up into the atmosphere meeting with the cooler air in the sky. Anytime you have the meeting two different temperatures, you will get air movement and the beginnings of condensation. The amount of wind and condensation depends on how drastically different the two temperatures are when they meet.

Condensation

This is a product of the glass convecting the cold temperature through it to meet the warm temperature inside. Condensation, if severe enough can be the cause of mold, wood rot and ruin your windows and cause serious health problems in a very short amount of time.

Solution?

There are very few manufacturers that make windows installable in the correct fashion, but actually Any window can be installed to minimize, if not eliminate, this issue.

First, remove the window and nail a 2x4 flush with the inside of the original framing. The new window you order will be the size of the opening between the 2x4's. It will come standard with a nailing flange all the way around the window.

Now nail the window into place by centering it in the opening, making sure that there are shims under the sill, and the window is plumb and level.

You will notice that instead of an extension of the jamb being needed on the inside, there is some space on the outside to cover. You can use cedar or have a local gutter contractor bend you some cap made out of extruded aluminum coil stock. Make sure you caulk the outside and seal the window inside with fiberglass stuffed around the edges, or window/door can foam. Simply Move the window trim to cover the new jamb and paint the drywall where the trim used to be.

You will notice that the window does not condensate anymore and there is not air moving around the window. It must be the window right? Actually no.

The Secret

By moving the window to the inside of the frame, it is directed closer to the warm side of the heating envelope. Because of this warm house temperatures are more prevalent and the warm air convects outside and forms the convective loop on the outside of the house. If there is condensation that forms, it will be on the exterior where the air can properly dry it and take it back into the atmosphere.

This method will not lower your energy bills and will not have any other effects other than removing the convective loop to the exterior of your home and eliminating moisture issues on your windows. There are many other methods of controlling window moisture. For most details on moisture control methods, see my article on HRV units and other Home Tips.

7 Tips for Installing a Shower Base

When you install a shower base flange in your bathroom, you want to be sure that the shower base floor is even, the drain connects to the waste water pipes correctly, and that the entire shower will be waterproof to prevent mold growth. Pay attention to these 7 tips for installing a shower base to create a functional, effective shower for your home.

Make Sure the Subfloor is Even and Level

Install your shower base only on top of a level subfloor. The shower base itself is sloped toward the drain hole to allow the water to exit down the drain smoothly and quickly. If the subfloor is tilted by even as little as an inch, the shower base drain will not work properly and your bathroom could be flooded.

Install Your Shower Base with the Proper Tools and Fasteners

Use only the screws, bolts and nuts from your shower base installation kit to attach it to the subfloor and the stud beam blocks. Changing to different fasteners will prevent a correct fit of the shower base flange and the drainpipe assembly, so your shower will not function correctly. The walls and floor of the bathroom could suffer damage from leaks and spillage.

Attach the Shower Base Flange to the Shower Walls

Place vertical blocks between the wall studs, cut to the height of the shower base flange. Attach the flange to these blocks and make sure it is level at the top. Slip narrow plastic or plywood shims between the metal flange and the wood blocks to ensure a snug, flush fit.

Make Precise Joins for the Drain Pipe Assembly

Use the drain fitting tool supplied with the shower base kit to thread the drain pipe to the drain hole precisely. Fit all washers tightly against the drain pipe nut before attaching the drain pipe assembly.

Cover the Shower Walls with Cement Board Before Tiling

Cement board is a non-permeable solid surface that when placed under tiles in a wet area such as a shower, virtually eliminates water leakage through the tile. It is heavy to install, so have two helpers handy to carry and support the board as you affix it to the wall studs with specially designed cement board screws. Insert the screws to just below the surface of the cement board to allow for level tiling.

Caulking and Grouting

Take great care with caulking and grouting to create a smooth, easily cleanable surface inside the shower. Match the color of the silicone caulk to the tile grout to make the shower walls and floor appear to be a seamless unit. Apply the caulking with a good-quality caulking gun to do the job as neatly as you can. Use a slender putty knife to grade the caulked surface to an even thickness.

With attention to these details, you will build a durable, functional shower that you will enjoy using for many years.

Tile the Shower Walls from the Floor Up

Laying tile on the walls from the floor upward will minimize the gap between the cement board wall and the shower flange top. You will fill this gap with silicone caulking later.

Trying to Replace Shower Arm

I'm trying to replace the shower head and arm with a new one without having to do too much.I live in an apartment.I was trying to unscrew the arm and it doesn't budge. The flange that goes into the wall isn't spackled on tightly.

So, it was easy to lift the flange and see that the arm going into the wall is covered with white spackle or something.I'm not sure what to do about this. Should I remove the spackle or whatever it is and then unscrew the shower arm?

It may be a water-based 'tub caulk' that set up and got brittle. They used that on the backside of the flange to keep the flange from falling away from the wall.

Some of the more expensive flanges are thicker and have a set screw in them. The cheaper ones are just friction fit, but often do not stay put. If that is the caulk I am thinking of, it has a reaction with moisture and turns into concrete. It is so tough to remove that if it is on a porcelain tub, it can actually take off the porcelain when you try to scrape it off! Take a guess how I know.

Try stabbing it with a sharp instrument or pointy nail and see if it is at all spongy. If not, you have some jackhammering to do, before you will be able to unscrew that arm.

The strange thing is it's not just around the flange; it's around the arm and the wall itself. The stuff around the flange was pretty goopy when I by hand removed the flange.

I just checked again. It's a little mushy but pretty firm; it looks like it's wrapped. The problem is it seems to go way into the wall. Well far enough that I can't see where the end goes!

Maybe I should just forget about replacing the arm. I was doing it for cosmetic reasons.

I've decided to leave it alone. Yep; I don't want to have to ask the landlord to come up after damaging something. A great guy and I don't want to put something else on his shoulders!

Thank you for your response though.

The arm is okay.It seems to me that there was duct tape around the arm; I guess it was to keep the flange from falling off which I don't see happening and also there aren't any leaks in the arm itself. Oh well, I cleaned it, with vinegar too; It's fine. I notice a tiny bit of corrosion but since overall it's just dandy, I'm not going to mess with it.

Any recommondations for how to make it stick fully to the wall again? I notice some excess water-based "tub-caulk" at the edge of the flange I may want to remove to make it look better. But it seems to me that the reason there is some caulk at the edge is because there is some open space there that the flange itself can't hide.

This shower is old and so I assume the reason there's so much of the caulk is to prevent leakage of any kind. It makes sense; until something needs to be replaced LOL.

However, the new showerhead seems to have much better water pressure which is great because I had to alert the landlord that the diverter wasn't working; the knob and flange came off (this is a three-knob shower; div being the center knob)... the result was water came through the tub faucet and through the shower as well when the knob was twisted one way; and when it was twisted the other way, completely out of the faucet.

The plumber I think did something with the diverter and sealed it all and the knobs work okay. But the problem was the water was still leaking a little bit from the faucet when it should be coming completely through the showerhead. The showerhead had much less water pressure.

In the future I may reapply the flange though as I loosened it to see what was behind it.The new showerhead's pressure seems to be really an improvement and the water coming out of the faucet is minimal. so I'm pleased with the way things turned out.

Digitech X Series Turbo Flange Pedal

Coming up with the right effects pedals to bring edge and personality to your sound is something that requires patience. It takes research, trial and error, and money to be able to figure out which pedals are going to suit you best. Flange is a cool way to add some richness to your guitar sound but it it is never easy figuring out which company provides the best value and which pedal is going to provide the most appropriate sound for you.

I think my personal favorite units are the ones created by Electro Harmonix. But after having worked in a music store for many years, I had the opportunity to try all kinds of flange units. I also spent, what some would consider, an exorbitant amount on those flange models. So here, Digitech offers a pretty respectable model for a smaller chunk of change. The Digitech X Series Turbo Flange is a stereo, 7 mode flanger effect. You can get a lot of richness from this one without taking a fat bite out of your wallet.

This pedal offers a lot more variety than I am typically used to seeing from Digitech. I do not think anyone can complain about this in a flanger unit. Variety cannot hurt in a pedal that is so singular in its direction. The first knob is for Speed. This will adjust the pace the frequency in which each wave length comes and goes.

To dial forward will achieve a direct quickened rate. Dialing way back will create a ton of atmosphere and fog out your guitar sound in a great way. Depth will mix the amount the effect has over your standard signal. Run this to ten to get full flange sounds. Bring back to 3 or 4 to mix flange with your dry signal. Regen will increase the intensity and stamina of the flange. The last knob is Type. This has seven selections and will let you choose any mode. These are Voice 1, Voice 2, Invert 1, Invert 2, Trigger Up, Trigger Down, and Step.

Effects pedals are a great way to expand and maximize tonal variety. Pedals can take even the best guitar players and transform their musical identity into something individual and tasteful. It is fortunate to be a player in the age of electronic equipment and devices. It has become easier than ever for any and all players to access awesome effects and do only a small amount of work to achieve music personality that can run forever. I have worked in music stores for a long time and have been fortunate enough to try almost all the major units on the market. The Ibanez CF7 Chorus Flange pedal is a pretty neat unit. This is probably not one that you would be after if you are a boutique collector. However, if you are a player that just needs some variance in your sound and cannot afford to spend a ton of money, this pedal will do you a solid.

The unique thing about this pedal is that it is a chorus and flange hybrid. The effect combination creates something magnificent and fresh. There are four knobs on the front of the pedal. The adjustments can be made by dialing the Speed, Depth, Delay Time and Regen buttons. Speed is going to adjust the pace of the wavering that happens with both chorus and flange. This effect can do it all. From gaseous and uncertain lengths to pitter-patter racing, you are covered. Depth will act as a leveler to determine how saturated you want your original tone to be with the effect. Delay time will clip the distance that it takes for the effect to resonate before trailing off. Regen will adjust the burst of waves that ring from each strum. The pedal also has two switches. Mode selects either chorus or flange. Krazy selects either Normal or Wack'd.

This is yet another awesome pedal from Ibanez with the "Tone-Lok" technology. By being able to hide your knobs inside the pedal by sliding inward, you are able to permanently store your settings until you want to change them. The dials will remain safe and unbroken forever. This is a great help and exhibits stern forward thinking.

As you can see, this unit offers a huge capacity for manipulating your flange range. This is a really cool unit and sounds respectable and clear. $80 is a fair price tag for this model.