Claims:WE CLAIM:
1. A smart H bayonet (100), comprising;
a ‘H’ shaped cross section (110) comprising two support plates at two
sides, connected each other with a node plate (112); and
a rubber gasket (120) embedded in each support plate of the bayonet;
characterized in that smart H bayonet (100) is configured to be
inserted or slided in female side Invisible PVC Flanges of a HVAC ducting
system, forming a flexible layer of rubber gasket on both sides of ‘H’
shaped cross section and preventing air leakage from gaps.
2. The smart H bayonet as claimed in claim 1, wherein the H shaped cross
section is symmetric to a vertical axis (116) of the smart H bayonet .
3. The smart H bayonet as claimed in claim 1, wherein each support plate has a
top end and a bottom end.
4. The smart H bayonet as claimed in claim 3, wherein both top end and
bottom end are inclined with a predetermined angle towards inner section of
the bayonet or the node plate.
5. The smart H bayonet as claimed in claim 1, wherein rubber gasket (120) is
designed to have a ‘V’ shape configuration.
6. The smart H bayonet as claimed in claim 1, wherein rubber gasket (120) has
an axis parallel to the node plate (112) and a horizontal axis of the smart H
bayonet.
7. The smart H bayonet as claimed in claim 1, wherein the rubber gasket (120)
is embedded at the center of each support plate.
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8. A method of fabricating a smart H bayonet (100), the method comprises the
steps of:
providing a raw material (205) comprising a plurality of compounds,
wherein the plurality of compounds comprises Resin, One Pack Flacks,
Titanium , Carbon Black, Calcium Steric (CS);
preparing a mixture of a plurality of compounds in a calculated
percentage weight;
pouring the mixture into a mixer machine (210) maintained at a
heating temperature up to 130 ?;
pouring the mixture from the from the mixer machine in a flat storage
plate (215) for cooling the mixture temperature to a room temperature;
supplying the mixture from the flat storage plate to a hopper (225) of
an extruder (220);
supplying the mixture into a barrel, head and common dye zones of
extruder (220) and simultaneously adjusting the temperature of the barrel,
head and common dye zones of the extruder (220) to provide an extrude;
supplying black granules of polyvinyl chloride (PVC) compound into
a hopper (235) of a co-extruder (230) connected with the extruder (220) and
simultaneously adjusting the temperature of the barrel to provide a rubber
gasket;
passing the extrude and the rubber gasket from the common dye zone
of both the extruder and co-extruder into a sizer (240) to reduce the
temperature of the extrude and the rubber gasket; and
cooling the extrude to provide a H-bayonet product (100) by
circulating water using a cooling tower (250).
9. The method as claimed in claim 8, wherein the method further comprises
passing the H-bayonet product through a conveyor belt (260).
10. The method as claimed in claim 8, wherein the method further comprises
cutting the H-bayonet by an automatic sensor controlled cutter (280).
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11. The method as claimed in claim 8, wherein the temperature of head zone of
extruder is maintained up to 210?, the temperature of common dye zone is
maintained up to 220?.
12. The method as claimed in claim 8, wherein the barrel of extruder is
maintained at three heating zones at a temperature 160?, 170? and 180?.
13. The method as claimed in claim 8, wherein the barrel of co-extruder is
maintained at two heating zones at a temperature 150? and 160?. , Description:TECHNICAL FIELD
[0001] The present disclosure relates to bayonet connectors, and more
particularly relates to a smart H shaped bayonet for preventing air leakages in Pre
Insulated Ducting systems.
BACKGROUND
[0002] A bayonet assembly is designed to couple two corresponding ends of
a connection quickly together, and is typically realized by providing a “male” end
on one section that mates with a corresponding “female” end on another section.
The respective ends are engaged and then twisted with respect to each other, for
example, by a quarter turn or less, to quickly couple and lock the two sections
together. Such bayonet connections are typically used in heating, ventilation, and
air conditioning (HVAC) systems, electrical systems, rigid hose connectors and
automobile systems.
[0003] Bayonets are designed to have various shapes, including T shape,
cylindrical shape, a ring shape and I or H shape. H shaped Bayonets are widely
used for Pre Insulated Ducting systems for joining two ducts together. However,
there are chances of air leakages in these systems at the connection of two Duct
pieces. H shaped bayonets are designed to have a slide-in PVC Profile as shown
in figure 1 and figure 2. H shaped bayonet is inserted between an invisible PVC
Channel profiles of HVAC Ducting System to hold the duct pieces together and
provides rigidity to the system. Leakage may happen due to a slight dimension
difference in the H Bayonet size and invisible profiles and the air may escape
from that area of interest. Such air leakage is a crucial factor in a clean room
environment, classified area, Pharmaceuticals and Hospitals. Such air leakage at
many of the site may cause pressure drop, non-uniform cool air propagation.
Moreover, the HVAC Ducting System is not leakage proof, and so more the
energy is required to cool the same area of the system.
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[0004] Further, there are conventional GI Ducts used as an alternate to preinsulated
ducting systems. MS Angle Flanges and Insulation Material on top of
the ducts are also used as an alternate to the current MS angle and GI ducting.
However, these conventional methods involve expensive components and manual
labor some.
[0005] Thus, there is a need for a H shaped bayonet with an improved and
cost effective design for preventing air leakages in HVAC Ducting System.
OBJECT OF THE INVENTION
[0006] It is the primary object of the present disclosure to provide a smart H
bayonet with built-in rubber gaskets for preventing air leakages in a HVAC
Ducting System.
[0007] It is another object of the present disclosure to provide a cost effective
method of fabricating a smart H bayonet for preventing air leakages in HVAC
Ducting System.
SUMMARY
[0008] In an aspect of the present disclosure, a smart H bayonet comprises a
‘H’ shaped cross section comprising two support plates at two sides, connected
each other with a node plate and a rubber gasket embedded in each support plate
of the bayonet. The smart H bayonet is configured to be inserted or slided in
female side Invisible PVC Flanges of a HVAC ducting system, forming a flexible
layer of rubber gasket on both sides of ‘H’ shaped cross section and preventing air
leakage from gaps.
[0009] In another aspect of the present disclosure, a method of fabricating a
smart H bayonet is disclosed. The method comprises the steps of providing a raw
material comprising a plurality of compounds, wherein the plurality of
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compounds comprises Resin, One Pack Flacks, Titanium , Carbon Black, Calcium
Steric (CS); preparing a mixture of a plurality of compounds in a calculated
percentage weight; pouring the mixture into a mixer machine maintained at a
heating temperature up to 130 ? and pouring the mixture from the from the mixer
machine in a flat storage plate for cooling the mixture temperature to a room
temperature. The method further comprises the steps of supplying the mixture
from the flat storage plate to a hopper of an extruder, supplying the mixture into a
barrel, head and common dye zones of extruder and simultaneously adjusting the
temperature of the barrel, head and common dye zones of the extruder to provide
an extrude, supplying black granules of polyvinyl chloride (PVC) compound into
a hopper of a co-extruder connected with the extruder and simultaneously
adjusting the temperature of the barrel to provide a rubber gasket, passing the
extrude and the rubber gasket from the common dye zone of both the extruder and
co-extruder into a sizer to reduce the temperature of the extrude and the rubber
gasket and cooling the extrude to provide a H-bayonet product by circulating
water using a cooling tower.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The detailed description is described with reference to the
accompanying figures.
[0011] Figure 1 illustrates a smart H Bayonet in accordance with an
exemplary embodiment of the present disclosure.
[0012] Figure 2, illustrates a flow chart with schematic for a method of
fabricating a smart H bayonet in accordance with another embodiment of the
present disclosure.
[0013] Figure 3 shows a table of compounds with a percentage weight used
for fabricating the smart H bayonet in accordance with a first example.
[0014] Figure 4 shows a table of compounds with a percentage weight used
for fabricating the smart H bayonet in accordance with a second example.
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DETAILED DESCRIPTION OF THE INVENTION
[0015] In this present disclosure, a new type H- Bayonet with built-in rubber
gaskets, called smart H bayonet is developed to overcome the leakage issues in
HVAC Ducting Systems and to provide zero leakage. Further, a method of
manufacturing the smart H bayonet is also disclosed. The smart H bayonet
enhances the rigidity of the system and reduces the air leakage factor to zero.
[0016] Referring to figure 1, illustrated is a smart H Bayonet in accordance
with an exemplary embodiment of the present disclosure. The smart H bayonet
100 comprises a symmetrical ‘H’ shaped cross section (110) comprising two
support plates (110a, 110b) connected each other with a node plate (112). The H
shaped cross section is symmetric to a vertical axis (116), comprises two sides.
Each support plate has a top end and a bottom end, both ends are inclined with a
predetermined angle towards inner section of the bayonet or the node plate.
[0017] Further, the smart H bayonet (100) comprises a rubber gasket (120)
embedded in each support plate of the bayonet on either sides. The rubber gasket,
in particular, is embedded at the center of each support plate. The rubber gasket is
designed to have a ‘V’ shape configuration and has an axis parallel to the node
plate and a horizontal axis of the smart H bayonet. The smart bayonet takes the
‘H’ shape of the profile, and is configured to be inserted or slided in female side
Invisible PVC Flanges of a HVAC ducting system. Thus, the smart H bayonet is
inserted between the invisible PVC Channel profiles to hold the duct pieces
together, forming a layer of gasket and preventing air leakage from gaps. The
flexible gaskets on both sides of H bayonet, lock the female component Flanges
and does not allow air to escape from the system.
[0018] Referring to figure 2, illustrated is a flow chart with schematic for a
method of fabricating a smart H bayonet in accordance with another embodiment
of the present disclosure. The smart H bayonet is manufactured by extrusion
process. The product composition comprises a PVC Compound of KV 8006 Black
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flexible granule recipe. The fabricating process comprises a plurality of steps
comprising preparing a mixture of calculated percentage of chemicals/compounds
and at the same time by considering the proper setting of an extruder machine, as
flexible Vinyl has wide range of hardness and density that vary according to
temperature. The melting temperature of Vinyl is set by adjusting the temperature
at various zones including barrel, head and dye. Once material is flowing through
the extruder, the temperature of each heating zone is adjusted depending on the
aesthetics and output of the material. The most critical zone is the rare barrel
temperature of the feed zone and the temperature of dye. The feed zone
temperature may control the compound sticking to the barrel wall. The dye
temperature may influence the output and may have an effect on the dimensions
of the extrude. A cold dye may restrict flow and too hot dye may affect
dimensions.
[0019] At the first step, a plurality of compounds (205) comprising Resin,
One Pack Flacks, Titanium , Carbon Black, Calcium Steric (CS) and Calcium
(CC) are mixed in a predetermined calculated percentage weight to form a
mixture. The mixture is poured into a mixer machine (210) at a heating
temperature maintained up to 130 ?. The quantity of the compound depends
upon the size of the mixer machine and the size of the hopper of the extruder
machine. The mixer machine (210) mixes all the compounds (205) at the
maintained temperature for a period of time, preferably about 20 to 25 minutes.
As soon as the mixture temperature reaches about 80 ?, Epoxy Dioxide
(Soyabean Oil) is poured along with the remaining mixture. The mixture is again
put into the process until the mixture temperature reaches to 130 ?. The final
mixture from the mixer machine is poured in a flat storage plate (215). In the
storage plate, the mixture is manually cooled down to a room temperature of 30
?. Once the mixture is maintained at the room temperature, the final mixture is
then poured into the hopper (225) of an extruder (220), the hopper capacity is
about 39 kg.
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Extruder:
[0020] The prepared mixture is poured into the hopper (225) of the extruder
(220) according to the batch. Quantity of materials depend upon the size of
hopper. In the extruder (220), two heating temperature zones are maintained at the
start of the Barell. The Temperature is maintained from 160 ? & rises upto
170?, the temperatures 160? & 170? is the first and second heating zone. The
rare end of the barrel is the third heating zone and the temperature of the third
heating zone is maintained at 180 ?. From the rear end of the barrel, the mixture
is passed to a head of the extruder. A Fourth heating zone is maintained at the
head at about 210? . The head of the extruder is one of the most critical part and
should be maintained carefully to avoid sticking of the material. After this the
mixture flows into the dye, the final zone temperature at the dye is set i.e. 220?.
Co-extruder:
[0021] A co-extruder (230) is connected with the extruder (220) sharing the
common extruder dye zone. In the co-extruder, the process of forming a Gasket is
performed. The compound Black Granule (KV8006) is poured into the hopper
(235) of the co-extruder (230), as shown in the figure 2 as compared to the other
material poured in the hopper of extruder 1. The co-extruder (230) has two
heating zones (237); in the co-extruder, the temperature in the barrel is maintained
at 150? and raises maximum upto 160? unlike the maximum temperature of
210? which is maintained at the extruder. In the co-extruder (230), it should be
noted that the gasket temperature is maintained maximum upto only 160?. The
black sticky Gasket material flows through a guide and gets stuck on both sides of
the co-extruder, forming a shape look like “H” in dye. The guide is equally
divided into two parts for forming the shape of “H”. The Gasket acts as a rubber
seal on final Bayonet assembly and provides Zero leakage. According to one
implementation of the present disclosure, 12 gm Granule is used to make Gasket
in 1 meter H-Bayonet.
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Sizer:
[0022] A final extrude at an output is then passed into a Sizer (240) at an
output of extruder unit (220), from both common extruder dye including Gasket.
The functions of the sizer (240) is to maintain exact shape and size to the final
product of Bayonet, according to the required dimensions.
Cooling Process:
[0023] The cooling process is conducted by cooling the final H-bayonet
product by using water through cooling tower (250), water is circulated
throughout the operation. Once the final extrude comes from dye to the sizer
(240), the temperature at 210? is dropped down to 15? to 10?. The sizer
temperature is always maintained at this temperature only. The final extrude after
cooling is checked and confirmed by conducting various quality test including
checking the tensile strength, yield strength, creek point and factor of failure to
check the required flexibility of the final Bayonet. Then the final H-bayonet
product is carried through conveyor belt (260) as shown in the figure 2. The final
H-bayonet is measured by a measurement unit (270) and cut by an automatic
sensor controlled cutter (280) according to the required length. The final product
(100) is collected and stored according to the number of pieces produced in a
batch. Normally, a 39 kgm batch produces around 400 meter H-Bayonet (100)
assembly.
[0024] The smart H-bayonet is developed to ensure 0% leakage at the joints
of ducts to optimize efficiency of cool air. The product composition consists of
PVC Compound and KV 8006 Black flexible granule recipe. Figure 3 shows a
table of compounds with a percentage weight used for fabricating the smart H
bayonet in accordance with a first example. In the first example, the weight about
97 gm/mtr H-bayonet is produced in a single batch.
[0025] Figure 4 shows a table of compounds with a percentage weight used
for fabricating the smart H bayonet in accordance with a second example. In the
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second example, the weight about 99.75 gm/mtr H-bayonet is produced in a single
batch.
[0026] The present disclosure proposed an improved design of the bayonet to
provide a leakage proof system. The present invention comes with a layer of
rubber which acts as a gasket to the inner walls of flange and prevent air transfer
to the other side of flange. Thus, making the system leak proof and eventually
conserving the overall energy. The smart H bayonet because of its built-in gasket
which when inserted between the PVC profile takes the shape of the profile and
fills the gaps to provide complete closure of the system and avoid leakage of air
through the gaps. The Smart H Bayonet is flexible in nature with a layer of rubber
and provides zero leakages in the HVAC systems. Further, installation process of
smart H bayonet is easy, involves low maintenance cost and saves energy when
installed.
[0027] Smart H Bayonet is mainly used in places where clean air is required
to maintain the best air volume within HVAC ducting system, heat ventilation &
air condition. Clean air is recommended to avoid formation of bacteria and
fungus. For example, Smart H Bayonets are used in cleanrooms, classified
projects, hospitals, pharmaceuticals, food industry applications.
[0028] Although the present disclosure has been described in the context of
certain aspects and embodiments, it will be understood by those skilled in the art
that the present disclosure extends beyond the specific embodiments to alternative
embodiments and/or uses of the disclosure and obvious implementations and
equivalents thereof. Thus, it is intended that the scope of the present disclosure
described herein should not be limited by the disclosed aspects and embodiments
above.