DESC:SMART PRE-INSULATED PIR FLAT OVAL DUCTING SYSTEM FOR AIR CONDITIONING AND METHOD OF MANUFACTURING THEREOF

TECHNICAL FIELD
[0001] The present disclosure relates to ducts for Heating, Ventilating and Air Conditioning ("HVAC") systems and, more particularly, to Smart Pre-Insulated PIR (Polyiso Cyanurate) Flat Oval Ducting Systems for Air Conditioning and to methods of manufacturing such ducting systems.

BACKGROUND
[0002] In most cases, an air-conditioning duct is installed in the ceiling or under the floor of a building by connecting a plurality of duct pieces to a necessary length. Air Conditioning ducts come with various shapes such as square, rectangular, circular, and flat oval. Conventionally square, rectangular Air ducts are used for centralized air-conditioning and placed to hide above false ceiling in buildings. Recently, architects tend to avoid false ceiling and provide ducts in open with rectangular shaped, as these shapes are too common and are aesthetically not preferable for architects and thus the need for the flat Oval Shape / Capsule Shape / Egg shape have been emerged. In oval shape ducts, surface had two-sided flat surface and two-sided half round means two same shape ducts with difference in size based on insulation thickness. Currently, these Air Conditioning systems use metal Ducts insulated internally with various insulation materials, for example XLPE (poly ethylene) and Nitrile rubber to prevent the condensation, and to reduce the travelling sound.

[0003] Further, space is another concern when installation of the air conditioning ducts inside the buildings, no one is ready to reduce head room space for HVAC Ducting systems. Developers want to minimize head room areas and maximize salable living space, and residents do not want to give more space for installation of heating and air conditioning ductwork or equipment so that they can maintain sufficient head room inside the living space. Further if the head room is small, flat oval duct is one of the best option as it requires less height and more width. The metal duct with insulation is very heavy and aesthetically poor due to various connections and joints, and such connections cannot be rectified at the site if any such connections have damaged during loading, unloading and transportation to various floors at sites and installation workmanship. This results in huge time delay to manufacture and bring the part quantities from the manufacturers again as the site fabrication is not possible with the conventional metal material.

[0004] Hence, there is a need for an airduct system to overcome all the disadvantages of the conventional systems discussed above.

OBJECT OF THE INVENTION
[0005] It is the primary object of the present disclosure to provide a Smart Pre-insulated PIR Flat Oval Ducting system for air conditioning.
[0006] It is another object of the present disclosure to provide a method of manufacturing a smart pre-insulated Flat Oval Duct for air conditioning systems.
[0007] It is still another object of the present disclosure to provide a method of manufacturing a continuous smart pre-insulated Flat Oval Duct for air conditioning systems.
[0008] It is still another object of the present disclosure to provide light weight, cost effective and fair aesthetic Flat Oval Ducts for air-conditioning systems.
SUMMARY
[0009] In one aspect of the present disclosure, a method of manufacturing a smart Pre-insulated PIR Flat Oval Ducts for air-conditioning is disclosed. In brief, the method comprises the steps of providing at least one panel of a predefined dimension having a top side, a bottom side, a first edge and a second edge, with the panel comprising an insulation sheet and at least one side of the panel is embossed with a thin metal surface, forming a cut with an angle on the first edge and the second edge of the panel, and forming a plurality of small groves with an angle and an equal spacing between each other, on at least one location of the panel. The plurality of small groves on at least one location of the panel are formed at a predefined distance from the first edge and a second edge of the panel. The method further comprises folding the panel and joining the first edge and second edge of the panel together to form a duct having at least one joint. The plurality of small groves are configured to bend when the panel is folded and to fill a gap there between to form the duct of a predefined shape. The method further comprises attaching a plurality of clamps on the at least one joint of the first edge and second edge on the panel and applying a tape over the top of the at least one joint and the plurality of clamps to provide an aesthetic look to the duct.

[0010] In another aspect of the present disclosure, a method of manufacturing a continuous pre-insulated PIR Flat Oval Duct for air-conditioning from a plurality of smart pre-insulated flat ducts is disclosed. Each smart pre-insulated flat ducts is manufactured using the previous aspect of the present disclosure. The method comprises providing a plurality of smart pre-insulated flat ducts, joining the plurality of smart pre-insulated flat ducts together by using a plurality of couplers, and applying an external adhesion tape on a plurality of joints of the plurality of smart pre-insulated flat ducts thereby forming a continuous smart pre-insulated flat duct system. The method further comprises joining the plurality of smart pre-insulated flat ducts in series to form a corner pre-insulated flat duct.

[0011] In yet another aspect of the present disclosure, a continuous smart pre-insulated flat duct system is disclosed. The system comprises a plurality of smart pre-insulated flat ducts, a plurality of couplers configured to attach with a plurality of smart pre-insulated flat ducts and an external adhesion tape applied on the joints of the plurality of smart Flat Oval Ducts. Each smart Flat Oval Duct comprises at least one panel having a top side, a bottom side, a first edge and a second edge, and at least one side of the panel is embossed with a thin metal surface. A plurality of small groves are formed with an angle and an equal spacing between each other, on at least one location of the panel. The plurality of small groves on at least one location of the panel are formed at a predefined distance from the first edge and the second edge of the panel. The panel is configured to fold to join the first edge and the second edge of the panel together to form a duct having at least one joint. The plurality of small groves are configured to bend when the panel is folded and to fill a gap there between to form the duct of a predefined shape. Further, the system comprises a plurality of clamps attached on the at least one joint of the first edge and the second edge on the panel and a tape applied over the top of the at least one joint and the plurality of clamps to provide an aesthetic look to the duct.

[0012] Further, a smart polyisocyanurate (PIR) Flat Oval ducting system for air conditioning system is disclosed. The present invention uses Smart PIR Panels for the fabricating the Flat Oval ducts. Both sides of the PIR Panels may be embossed with Aluminium surface (foil). Panels of predefined length are generated by cutting the sheet as per the duct size requirement and processed further on a CNC machine. The CNC machine cuts small groves/V-cuts with a specific angle for a circular shape and provides a 45-degree cut on the edges of the panel. When the PIR sheet is folded, all V-cuts on the panels at predefined locations from both the edges and center of the sheet fill the gap and take a firm shape of semi-circle on two sides thereby forming an oval shape duct. Further, a plurality of tiger clamps attached on the joint of sheets at a predefined distance from each other and an Aluminium tape is applied over the joint and tiger clamp giving an aesthetic look to the ducts.

[0013] Further, the CNC machine may cut the duct moderately on the front so as to connect with another duct by means of a metal coupler. A duct may be inserted into another duct along with the metal coupler and form a coupling between two ducts. An external strong adhesion tape is applied on the coupling, and two or more such ducts may be joined in series in the manner as above to form a continuous and lengthy air-conditioning oval ducts as required. In the embodiments, PIR Panels may be converted into straight oval ducts and corner oval ducts based on the air conditioning requirements.

BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The detailed description is described with reference to the accompanying figures.
[0015] Figure 1 (a) illustrates a top view of a flat PIR panel/sheet used for fabricating a smart Flat Oval duct system.
[0016] Figure 1 (b) illustrates a side view of flat PIR panel/sheet having an embossed Aluminium surface on both top and bottom sides, used for fabrication of Flat Oval ducting System for air-conditioning in accordance with the present disclosure.
[0017] Figures 2 (a)-(b) illustrate a top and side view of small groves and 45-degree cuts made on the PIR Panels for a circular shape in accordance with the present disclosure.
[0018] Figure 2(c) illustrates a table representing a number of V-cuts and degree of V-cuts made on a 20 mm thick PIR panel based on the size and diameter requirement.
[0019] Figures 3 (a)-(b) illustrate the PIR sheet folded to obtain a semi-circle shape on two sides of PIR sheets.
[0020] Figure 4 illustrates edges of the PIR sheets joined together to form a Flat Oval shape duct in accordance with the present disclosure.
[0021] Figure 5 illustrates the plurality of tiger clamps with teeth in accordance with the present disclosure.
[0022] Figure 6 illustrates a number of tiger clamps fixed at a predefined distance to each other to intake a top center joint.
[0023] Figure 7 illustrates an Aluminium tape applied over the top central joint and tiger clamps giving an aesthetic look to the oval ducts.
[0024] Figure 8 illustrates a metal coupler with groove used for joining one or more Flat Oval duct pieces , prepared by using the CNC machine.
[0025] Figure 9 illustrates one side of the coupler inserted into an inner side of a first flat oval duct.
[0026] Figure 10 illustrates a second duct sliding on the other side of the coupler to join two flat oval ducts to form single piece .
[0027] Figure 11 illustrates a continuous PIR Flat Oval Ducting system with two smart Flat Oval ducts joined together in accordance with the present disclosure.
[0028] Figure 12 illustrates a plurality of PIR sections cut/made by the CNC machine for fabrication of corner/bend piece of Flat oval ducting system.
[0029] Figure 13 illustrates a plurality of PIR sections or sheets with a plurality of small groves and cut edges.
[0030] Figure 14 illustrates a plurality of smart pre-insulated flat ducts for a corner flat oval duct made from a plurality of PIR sheets.
[0031] Figure 15 (a) illustrates a plurality of smart pre-insulated flat duct pieces joined in series to obtain a corner or bend of flat oval duct in accordance with the present disclosure.
[0032] Figure 15 (b) illustrates the Aluminium tape applied over all joints and tiger clamps giving an aesthetic look to the corner or bend of flat oval duct.
[0033] Figure 15 (c) illustrates the corner or bend of flat oval duct with the metal coupler in accordance with the present disclosure.
[0034] Figure 16 illustrates a continuous PIR Flat oval ducting system (500) with the corner or bend duct and the straight duct of flat oval duct joined together.

DETAILED DESCRIPTION OF THE INVENTION
[0035] A smart Polyiso Cynurate (PIR) Flat Oval ducting system for air conditioning and a method of manufacturing the same are disclosed. The smart air-conditioning Flat Oval ducts are made of polyisocyanurate (PIR), light in weight, aesthetically good and provide faster installation. Overall, these PIR Flat Oval Ducting System for air-conditioning offer a better techno commercially system with possibility of modification of shapes all at site without the need of ordering a new material from a factory again. Further, the smart air-conditioning PIR Flat Oval ducts can also be painted to blend with the aesthetic of the space with vibrant color if required.

[0036] The present invention uses Smart pre insulated PIR Panels for the fabrication of Flat Oval Ducting System. The smart panels are made of polyisocyanurate (PIR) insulation sheets, and each panel has a top side and bottom side. Both the top and bottom sides of the PIR Panels/sheets may be embossed with an Aluminium surface (foil). The embossed surface has a thickness ranging from 80 microns to 200 microns. The Aluminium foil is embossed so that the adhesion of foam with the skin is intact during the manufacturing process.

[0037] In one example of the present invention, the PIR panels has a thickness about 20 mm and Aluminium foil having a thickness about 80 microns is embossed on both sides of PIR panels. These PIR Flat Oval Ducting System can be used as a replacement of conventional Ducting System. Since both the top and bottom sides of PIR panels Embossed with 80 microns, the cost of the product is comparatively low. The external surface of the product may be painted with a logo or any aesthetic effect if required.

[0038] In another example of the present invention, the PIR panels has a thickness ranging from 15 mm to 30mm and Aluminium foil having a thickness about 80 microns is embossed on one side of PIR panels and Aluminium foil having a thickness about 200 microns is embossed on another side of PIR panels, Higher thickness on external surface increases the mechanical strength on the external surface as per design requirement. Since the external surface is embossed with Aluminium of 200 micron, the ducting system is more rigid when installed without ceiling, however the cost of the ducting system may be higher than the ducts with 80 mm embossed Aluminium on both sides. Further, the external surface of the product may be embossed with or without a logo or any aesthetic effect if required. The internal surface is normally embossed with logo, however, the external surface without logo may be preferred by the customers/users as the ducts are installed in open spaces, where customers/users will not prefer the logo of the manufacturer. The thickness of the embossed external surface may vary from 80 micron to 200 microns. Further, the thickness of the PIR panel may vary based on the requirement, from 15mm to 30mm. In one implementation of the present invention, either the top side or the bottom side of the PIR panel is embossed with the Aluminium foil.

[0039] In some embodiments of the present disclosure, a method of fabrication of smart PIR Flat Oval Ducting system for air-conditioning is disclosed. For the fabrication, plain flat PIR sheets/panels with a predefined dimensions can be taken for the process into a CNC machine. The method illustrates the conversion of plain PIR sheets into predefined shape of ducts. The smart air-conditioning duct may be formed into a pre-defined shape selected from an oval shape and a triangular shape. Referring to figure 1 (a), illustrates a top view of a flat PIR panel/sheet used for fabrication a smart air-conditioning ducting system. Referring to figure 1 (b), illustrates a side view of the flat PIR panel/sheet having an embossed Aluminium surface (207) on both top and bottom sides, used for fabricating a smart air-conditioning duct system. The flat panel (200) comprises a plain PIR insulation sheet (205) with the top side (201) and the bottom side (202), the first edge (220) and the second edge (230) as shown in figures 1 (a) & (b). A computer program may be generated and stored in the CNC machine based on CAD/CAM drawings of sheets generated as per the size requirement of ducts. Panels of predefined length, width and thickness may be generated by cutting the flat sheet as per the duct size requirement and processed further on the CNC machine. In some examples of the present invention, PIR Panels having size 1.2 M X 4 M (W x L) are used for fabrication of PIR Flat Oval Duct for air-conditioning ducts. The length of the panels can be customized to optimize the wastage to produce the desired sizes.

[0040] As shown in figures 2 (a)-(b), the CNC machine further cuts a plurality of small groves (210) with a specific angle for a circular shape and provides a 45-degree cut on the first edge (220) and the second edge (230) of the panel for joining the panels to form the duct. The angle of the cut on the first edge (220) and the second edge (230) varies from 30 degrees to 60 degrees. In the embodiment of the invention, angles of the cut on the first edge (220) and the second edge (230) make a complementary angle together. In the example of the present invention, the angle of the cut is selected as 45 degrees. The plurality of small groves (210) may comprise a plurality of V-cuts cut at a predefined depth and an angle leaving some portion of thickness of panels uncut to form a round/circular shape when the panels are folded. Number of V-cuts and degree of V-cuts may depend on diameter of duct. For an example of 20 mm thick PIR panels, V-cuts are made at depth of 18 mm leaving 2 mm thickness uncut to maintain strength of a round/circular shape and total of 20 cuts, 10 cuts are made at a distance from each edge of the sheet, are made to fabricate a 150 mm diameter duct. Alternatively, the plurality of V-cuts made at two locations on the panel, each location has a predefined distance from the edges and center of the panel. Similarly, the plurality of V-cuts may be made at n number of locations based on a requirement.

[0041] Referring to Figure 2(c), illustrates a table representing a number of V-cuts and degree of V-cuts made on a 20 mm thick PIR panel based on the diameter requirement. For another example, requirement of duct size having dimensions: 500 mm X 200 mm X 1200 mm (W x H x L), the width of duct is shown as 500 mm, Height of the duct as 200 mm and the length of the duct as 1200 mm, the diameter of Flat oval duct for air-conditioning system is 200 mm. The Flat oval duct has two semi-circle portion formed at a predefined distance from both the edges and center & a flat portion at its center. The length of the center flat portion is calculated as:
LC= Width – Height = 500-200 = 300 mm; (1)

And the perimeter of semi-circle portion is calculated as:
P= 3.14 * height/2 = 3.14*200/2 = 314 mm (2)

[0042] The total number of V-cuts to be made is 24 as per the table 1 shown in figure 2 (c) for the perimeter length 314 mm having a diameter of 200 mm. The total number of 24 V-cuts is divided equally for both semi-circles, i.e., 24/2, 12 V-cuts are made on each side. A center line for these V-Cuts on the perimeter of this semi-circles is calculated as: =P/12 = 314/12 = 26.17 mm, i.e., a gap between center of two V-Cuts is 26.17 mm. The center lines for these V-Cuts on the perimeter are marked and a degree of the blade in the CNC machine is set as 7.5 and the center point of the cutter is places on the marked center lines on the perimeter of the panels. Initially, a center line is selected, and a right-hand side of line is cut and then a left-hand side of line is cut. With both the side cuts made, a 15 Degree V-cut is generated at the center line.

[0043] The above steps are repeated for all marked center lines on the perimeter. When the PIR panels are folded, these V-Cuts are bent into a semi-circle or a round side of the duct having 180 degrees, i.e., 12*15= 180 degrees. Similar steps are repeated for forming semi-circle on the other side of PIR panels. The center flat portion at the bottom is joint free and the top flat portion has a joint at its center. The top Joint may be made by making Male, Female 45 degrees cuts on the edges of the panels and joining together. The plurality of V-Cuts are made at an angle ranging from 6 degrees to 36 degrees, preferably in the range from 10 degrees to 20 degrees and most preferably made at angle of 15 degree.

[0044] Figures 3 (a)-(b) illustrate the PIR sheet folded to obtain a semi-circle shape on two sides of PIR sheets. As shown in figures 3 (a)-(b), the PIR sheet (200) is folded and both the first and second edges (220, 230) of the PIR sheet are bonded together by applying glue (240) on edges of the duct. When the PIR sheet is folded, all V-cuts (210) on the panels at predefined locations from both the edges and center of the sheet fill the gap and take a firm shape of semi-circle on two sides. The glue (240) is applied on inner side of cut or edge surface, and a proper drying time should be given before the edges joining together. Figure 4 illustrates edges of the PIR sheets joined together to form a Flat Oval shape duct in accordance with the present disclosure. The first (220) and second (230) of the panels joined together as shown in figure 4, creating a top joint (235) as a center point on a flat surface of the oval duct. Then, a plurality of tiger clamps (250) with teeth are used to strengthen the top duct joint (235).

[0045] Referring to figure 5, illustrates the plurality of tiger clamps (250) with teeth in accordance with the present disclosure. A number of tiger clamps (250) with glue (240) applied on the inner side of clamps, are attached on the top joint (235) and maintaining the top joint (235) as a center point as shown in figure 6. The tiger clamps are attached at a predefined distance from each other. In one example of the present invention, the plurality of tiger clamps are fixed at distance of 300 mm from each other. Finally, an Aluminium tape (260) is applied over the top central joint (235) and the plurality of tiger clamps (250) giving an aesthetic look to the oval ducts and forming the smart pre-insulated flat oval duct (270) as shown in figure 7.

[0046] In further steps, the cutter may be moved in a front direction to generate a cut on the sheet in a depth about 17 mm. The cutting speed is moderate with a maximum length of the sheet without stopping so as to prevent uneven profile on the sheets. After completing the cut generated profile, a second duct of similar profile is prepared by the CNC machine by repeating the same steps as discussed above.

[0047] Referring to figure 8, illustrates a metal coupler (280) with groove used for joining one or more duct models/pieces prepared using the CNC machine as discussed above. An adhesive or glue (240) is applied on both sides of the coupler and one side of the coupler is inserted into the inner side of a first duct (270a) as shown in figure 9. The next duct (270b) slides on the other side of the coupler (280) and forms two oval ducts as shown in figure 10. The two ducts (270a, 270b) are overlapped on the same metal coupler (280). The metal coupler (280) acts as an internal stiffener and a joining medium for two duct pieces. Once the two duct pieces (270a, 270b) are inserted in the coupler (280), an external strong adhesion tape (295) of strong suitable size is applied on the duct coupler joint (290) as shown in figure 11. It may be understood that two or more oval ducts may be joined in series in such manner as above to form a continuous and lengthy ducts for air-conditioning as required. A plurality of joints may be formed, when two or more oval ducts are joined in series, and the external strong adhesion tape (295) may be applied on the plurality of joints of ducts. Figure 11 illustrates a continuous PIR Flat Oval Ducting system (300) with two smart Flat Oval ducts (270a, 270b) joined together in accordance with the present disclosure. Figures 7 and 11 illustrate straight Flat oval ducts used for HVAC system in accordance with the present disclosure.

[0048] Referring to figure 12, illustrates a plurality of PIR sections (400a, 400b, 400c, 400d) cut/made by the CNC machine for fabrication of corner/bend piece of Flat oval ducting system. The plurality of PIR sections (400a, 400b, 400c, 400d) may have different dimensions of length and width. Each PIR section (400a) has a top side , a bottom side , a first edge (420) and a second edge (430) as similar to the PIR panel in the figures 1 (a) - 1(b). Further, each PIR section has a plurality of small groves or V-cuts and edges of PIR section with 45 degree cut as similar to the previous embodiment shown in Figures 2 (a) -2 (b). Referring to figure 13, illustrates a plurality of PIR sections or sheets with a plurality of small groves (410) and cut edges (420, 430). Referring to figure 14, illustrates a plurality of smart pre-insulated flat duct pieces (450a, 450b, 450c, 450d) for a corner oval duct made from a plurality of PIR sheets. Each air conditioning duct piece is formed by folding the each PIR sheet and by joining the first and second edges of the sheet. Thus, the smart pre-insulated flat duct pieces are made as similar to the above embodiments, for a corner/bend section.

[0049] Referring to figure 15 (a), illustrates the plurality of Flat oval Duct pieces joined in series to obtain a corner/bend of flat oval ducting system in accordance with the present disclosure. The plurality of flat oval duct pieces (450a, 450b, 450c, 450d) may be joined using a strong adhesive or glue. Alternatively, a front and rear edges of the sheets are made with a cut of angle 45 degree, or in a range selected from 30 degree to 60 degree. The glue may be applied on the front and rear edges of each smart pre-insulated flat duct, and the plurality of flat oval duct pieces may be joined together by bonding rear and front edges of the duct pieces for the corner area. Upon joining the plurality of flat oval ducts pieces to form a corner or bend, a plurality of tiger clamps (250) with glue applied on the inner side of clamps are attached on various joints of each section and the duct piece as shown in figure 15 (a). The tiger clamps (250) are attached at a predefined distance from each other as similar to the above embodiments. In one example of the present invention, the plurality of tiger clamps are fixed at distance of 300 mm from each other. Further, an Aluminium tape (260) is applied over all joints and tiger clamps giving an aesthetic look to the corner Flat oval duct as shown in figure 15 (b). A metal coupler (280) as shown in figure 8, may be used to connect the corner duct section with another straight duct as shown in figure 7 of the above embodiment. Figure 15 (c) shows the corner Flat oval duct (470) with the metal coupler (280) in accordance with the present disclosure. A continuous PIR Flat oval ducting system (500) with the corner duct and the straight duct joined together is shown in figure 16. The joint of the corner duct and straight duct may be covered using the strong adhesion tape (295). The duct surfaces need to be cleaned properly for no dust, no oil presence on surface of foil before fixing. The above steps are continued till entire duct of the predefined length is obtained.

[0050] The present invention uses a novel PIR Panel to increase the rigidity of the Pre-Insulated Flat Oval Ducting System and enhance the overall strength of the System. The metal coupler is designed to sustain both low and medium pressure airflow with low leakage levels when compared conventional technologies. The coupler also acts as stiffeners so that there is no bulging / sagging of the duct. The PIR Flat Oval Ducts can be painted with any desired colours to match the ambience of the room. With these air ducts, scope of designing increases due to the enhanced capability of manufacturing these ducts in any sizes as against conventional metal Spiral Flat Oval Duct. Any site can be easily modified with this ducting system. Further, logistic challenges are reduced as the material can be transferred in sheet/panel form also as against finished shapes, which ultimately reduces the transportation cost.

[0051] The disclosed of Smart Pre-insulated PIR Flat Oval Ducting System replaces the conventional metal Flat oval ducts with the Insulation. The limitation in the production capacity constraints in the conventional methods makes Architects and users to use PIR Flat Oval ducting system in projects requiring high volume of ducts.

[0052] 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 hat 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.
,CLAIMS:WE CLAIMS

1. A method of manufacturing a smart pre-insulated flat duct, the method comprising:
providing at least one panel (200) of a predefined dimension having a top side (201), a bottom side (202), a first edge (220) and a second edge (230), wherein the at least one panel (200) comprises an insulation sheet (205) and at least one side of the panel (200) is embossed with a thin metal surface (207);
forming a cut with an angle on the first edge (220) and the second edge (230) of the panel (201);
forming a plurality of small groves (210) with an angle and an equal spacing between each other, on at least one location of the panel (200), wherein the plurality of small groves (210) on at least one location of the panel are formed at a predefined distance from the first edge (220) and the second edge (230) of the panel (200);
folding the panel (200) and joining the first edge (220) and the second edge (230) of the panel together to form a duct having at least one joint (235), wherein the plurality of small groves (210) are configured to bend when the panel (200) is folded and to fill a gap there between to form the duct of a predefined shape;
attaching a plurality of clamps (250) on the at least one joint (235) of the first edge and the second edge on the panel; and
applying a tape (260) over the top of the at least one joint (235) and the plurality of clamps (250) to provide an aesthetic look to the duct.

2. The method as claimed in claim 1, wherein the insulation sheet (205) is made of polyisocyanurate (PIR).

3. The method as claimed in claim 1, wherein the predefined shape of the smart pre-insulated flat duct is an oval shape.

4. The method as claimed in claim 1, wherein the thin metal surface (207) is an Aluminium surface having a thickness ranging from 80 micron to 200 microns.

5. The method as claimed in claim 1, wherein providing at least one panel (200) of predefined dimension comprises generating at least one panel (200) with a predefined length, width, and thickness by cutting a flat sheet using a CNC machine.

6. The method as claimed in claim 1, wherein the cut is formed at the angle ranging from 30 degree to 60 degree, on the first edge (220) and the second edge (230) of the panel (200) using the CNC machine.

7. The method as claimed in claim 1, wherein joining the first edge (220) and the second edge (230) of the panel (200) together comprises connecting both the edges of panel by applying glue (240) on the edges.

8. The method as claimed in claim 1, wherein a plurality of clamps (250) comprise a plurality of tiger clamps with teeth attached at a predefined distance from each other on the panel.

9. The method as claimed in claim 1, wherein the plurality of small groves (210) comprise a plurality of V-cuts made at a predefined depth and an angle and by leaving some portion of thickness of panels uncut to form a predefined shape when the panels are folded.

10. The method as claimed in claim 1, wherein a plurality of V-cuts are made at an angle ranging from 6 degrees to 36 degrees.

11. A method of manufacturing a continuous smart pre-insulated flat duct system (300), from a plurality of smart pre-insulated flat ducts, each flat duct is manufactured using various steps as claimed in claim 1, wherein the method comprising:
providing a plurality of smart pre-insulated flat ducts (270a, 270b);
joining the plurality of smart pre-insulated flat ducts (270a, 270b) together by using a plurality of couplers (280); and
applying an external adhesion tape (295) on a plurality of joints (290) of the plurality of smart pre-insulated flat ducts (270a, 270b).

12. The method as claimed in claim 11, wherein the method further comprises joining the plurality of smart pre-insulated flat ducts (400a, 400b, 400c, 400d) in series to form a corner pre-insulated flat duct (470).

13. The method as claimed in claim 11, wherein each coupler is made of a metal.

14. A continuous smart pre-insulated flat duct system, the system comprising:
a plurality of smart pre-insulated flat ducts (270a, 270b), wherein each smart pre-insulated flat duct comprises:
at least one panel (200) having a top side (201), a bottom side (202), a first edge (220) and a second edge (230), wherein the at least one panel comprises an insulation sheet (205) and at least one side of the panel (200) is embossed with a thin metal surface (207) and a cut is formed with an angle on the first edge (220) and the second edge (230) of the panel (201);
a plurality of small groves (210) formed with an angle and an equal spacing between each other, on at least one location of the panel (200), wherein the plurality of small groves (210) on at least one location of the panel are formed at a predefined distance from the first edge (220) and the second edge (230) of the panel;
wherein the panel (200) is configured to fold to join the first edge (220) and the second edge (230) of the panel together to form a duct having at least one joint (235), wherein the plurality of small groves (210) are configured to bend when the panel is folded and to fill a gap there between to form the duct of a predefined shape;
a plurality of clamps (250) attached on the at least one joint (235) of the first edge (220) and the second edge (230) on the panel; and
a tape (260) applied over the top of the at least one joint (235) and the plurality of clamps (250) to provide an aesthetic look to the duct;
a plurality of couplers (280) configured to attach with a plurality of smart pre-insulated flat ducts (270a, 270b); and
an external adhesion tape (295) applied on a plurality of joints (290) of the plurality of smart pre-insulated flat ducts (270a, 270b).