Note: Descriptions are shown in the official language in which they were submitted.
CA 02622061 2012-10-11
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ARCUATE SADDLE WITH PARTIAL RIBS AND METHODS OF
MANUFACTURE
This application claims the benefit of U.S. provisional application Serial
No. 60/891,098 filed on February 22, 2007.
BACKGROUND OF THE INVENTION
Aspects of the present invention relate generally to saddles for anchoring
and supporting insulated and uninsulated pipes. Saddles are typically used in
building construction to anchor and support pipes to suspend the pipes from
the
structure of the building. Saddles typically spread the force of a hanger
across a
portion of the pipe to minimize the force applied to a particular spot.
Arcuate flat
saddles and saddles with 180 arcuate ribs (FIG. 1) are well known in the art.
An
improved saddle is desired.
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SUMMARY
Embodiments of the present invention relate to arcuate saddles with partial
ribs
typically used to anchor and suspend insulated or non-insulated pipes. Partial
ribs on the
lower face of the saddle inhibit the saddle from sliding relative to the
hanger when engaged
and provide strengthening force to the saddle.
In certain embodiments of the present invention, an arcuate saddle comprises a
saddle which has a length and a width formed into an arc defined by a radius.
The arcuate
saddle further includes an exterior face on the saddle and a pair of partial
ribs with closed ends
protruding from the exterior face.
In certain embodiments of the invention, there is provided an arcuate saddle
for
supporting pipe, comprising: a saddle having a length and a width, wherein the
width is
formed into an arc defined by a radius; an interior channel defined by said
saddle, said
channel extending the length of said saddle said interior channel defining
corresponding
opposing vertical side portions and a lower face portion on an exterior face
of said saddle;
and, a pair of protruding partial ribs on said lower face portion of exterior
face, wherein said
partial ribs have length direction parallel to said width and wherein the
length of said partial
ribs is less than said saddle width wherein each said partial rib includes a
central peak section
and opposing slanted sides extending from said exterior face to said peak
section, and wherein
the ends of said partial ribs are closed and wherein the ribs provide
strengthening force to the
saddle, and; wherein said partial ribs are defined on said lower face portion
substantially
transverse to the length of said saddle and wherein said partial ribs do not
substantially extend
into said side portions.
In certain embodiments of the invention, there is provided an arcuate saddle
for
supporting pipe, comprising: a saddle having a length and a width, wherein the
width is
formed into an arcuate bend defined by a radius, wherein said arcuate bend
extends less than
or substantially equal to 180 degrees; an interior channel defined by said
saddle, said channel
extending the length of said saddle said interior channel defining
corresponding opposing
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vertical side portions and a lower face portion on an exterior face of said
saddle; and, a pair of
protruding partial ribs on the lower face portion of the exterior face of said
saddle, wherein
each said partial rib includes a central peak section and opposing slanted
sides extending from
said exterior face to said peak section, wherein said partial ribs have an
arcuate bend
extending along said saddle arcuate bend and a length direction extending
along said saddle
arcuate bend, and wherein the degrees that said partial ribs extend is less
than the arcuate bend
of said saddle and wherein the ends of said partial ribs are closed and
wherein the ribs provide
strengthening force to the saddle.
In certain embodiments of the invention, there is provided an arcuate saddle
for
supporting pipe, comprising: a saddle with a length and a width formed into an
arc defined by
a radius and wherein said saddle defines an interior channel extending the
length of said
saddle, said interior channel defining corresponding opposing vertical side
portions and a
lower face portion on an exterior face of said saddle; and, a pair of partial
ribs with closed
ends protruding from said exterior face, wherein each said partial rib
includes a central peak
section and opposing slanted sides extending from said exterior face to said
peak section and
wherein the ends of said partial ribs are closed; wherein said partial ribs
are defined on said
lower face portion substantially transverse to the length of said saddle and
wherein said partial
ribs do not substantially extend into said side portions and wherein the ribs
provide
strengthening force to the saddle.
Objects, features and advantages of the present invention shall become
apparent from the detailed drawings and descriptions provided herein.
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BRIEF DESCRIPTION OF THE DRAWINGS
FIG. I is a perspective view of a prior art saddle with 180 arcuate ribs.
FIG. 2 is an example of a hanger assembly usable to suspend saddles
according to embodiments of the present invention.
FIG. 3 illustrates a hanger assembly and saddle supporting a pipe according
to a preferred embodiment of the present invention.
FIG. 4 is lower perspective view of an arcuate saddle according to one
embodiment of the present invention.
FIG. 5 is a lower view of the saddle of FIG. 4.
FIG. 6 is side view of the saddle of FIG. 4.
FIG. 7 is a downward or interior view of the saddle of FIG. 4.
FIG. 8 is a die usable to make arcuate saddles according to embodiments of
the present invention.
FIG. 9 is an enlarged partial view of the die of FIG. 8.
FIG. 10 is a cross-sectional view of a die assembly usable to make arcuate
saddles according to embodiments of the present invention.
FIG. 11 is a cross-sectional view of a die assembly usable to make arcuate
saddles according to embodiments of the present invention.
FIG. 12 is a framed view of a roll bending machine to make arcuate saddles
according to embodiments of the present invention.
FIG. 13 is a framed view of an optional sensor assembly on the machine of
FIG. 12.
FIG. 14 is a perspective view of the die assembly of FIG. 10 with a sensor.
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DESCRIPTION OF PREFERRED EMBODIMENTS
For the purposes of promoting an understanding of the principles of the
invention, reference will now be made to the embodiments illustrated and
specific
language will be used to describe the same. It will nevertheless be understood
that
no limitation of the scope of the invention is thereby intended, such
alterations,
modifications, and further applications of the principles of the invention
being
contemplated as would normally occur to one skilled in the art to which the
invention relates.
Embodiments of the present invention relate to arcuate saddles with partial
ribs typically used to anchor and suspend insulated or non-insulated pipes. As
illustrated in FIGS. 2 and 3, in a typical assembly 10 a hanger assembly 20
wraps
around a pipe or insulated pipe 15 with a saddle 30 situated between the lower
portion of the hanger and the pipe. According to an embodiment of the present
invention, partial ribs 50 on the lower face of the saddle inhibit the saddle
from
sliding relative to the hanger when engaged and provide strengthening force to
the
saddle.
When putting together assembly 10, an installer takes saddle 30 and slides
it through lower bracket 24 of hanger 20 either independently or with the
introduction of pipe 15 into the hanger. Partial ribs 50 are generally on the
lower
face or side of saddle 30 and do not extend upward to the vertical sides. The
vertical sides of saddle 30 have a width in a close tolerance with the
interior of
hanger lower bracket 24 to transfer suspension force from the pipe to the
hanger
once in place. Typically the ribs in a prior art saddle, such as 180 ribs
shown in
FIG. 1, have a higher profile and larger radius than the interior of hanger
particularly on the sides, making sliding introduction of the prior art
saddles into
the hanger difficult. Omitting rib portions from.the sides of the saddle
allows the
saddle to be introduced with a slight lifting above the lower hanger portion
to clear
the lower ribs, but without concern for side rib portions which might
otherwise
require lifting or twisting of the saddle relative to the hanger sides.
Partial ribs 50 according to certain preferred embodiments are considered
closed at their ends, for example with the ends tapered into the face of the
saddle.
Closing the ends and omitting rib portions from the sides of the saddle allows
the
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lower hanger portion to engage the sides of the saddle and pipe 15 in a flush
or no-
gap arrangement between the saddle side and hanger and between the saddle side
and pipe and preferably with a friction fit once engaged. This flush
arrangement
substantially closes and seals the hanger to the saddle side and the saddle to
the
pipe and prevents the accumulation or retention of moisture or debris in the
rib,
such as water, dust, mold, or bacteria, which could accumulate in an open
ended
rib, such as in the 180 degree arcuate ribbed saddle of FIG. 1.
Hanger 20, for example the clevis hanger illustrated in detail in FIG. 2,
typically includes an upper portion or bracket 22 which can be suspended from
a
building structure, a lower bracket 24 for receiving and engaging the saddle
and
pipe and optionally includes a pivot 26 between the upper and lower brackets
to
allow some relative movement of the hanger portions, if necessary due to
vibration, expansion or contraction. Alternately, the hanger can be one piece
or a
strap which suspends a pipe and saddle.
FIGS. 4-7 illustrate saddle 30 according to one preferred embodiment.
Saddle 30 is formed typically from a metal sheet 32 pressed or rolled into
approximately a 180 arcuate bend about a radius R, forming a length L and a
width W. Saddle 30 includes two ends 33 and 34 at opposing ends of the saddle
length. Ends 33 and 34 are optionally slightly outwardly flared 35 at each end
to
facilitate introduction of the pipe into the saddle and to minimize any
abutment of
sharp edges against the pipe or insulation. The exterior face of saddle 30
includes
a generally lower portion or lower face 38 and opposing vertical sides 39.
"Vertical" and "lower" references herein refer to arcuate or curved portions
of the
saddle which may include generally vertical or horizontal tangents and are not
intended to imply planar or flat portions.
The outer diameter or width W of saddle 30 is preferably sized to closely
correspond to the inner diameter or width Wc of the lower bracket 24 of hanger
20.
As examples, pipe sizes may range from 0.5 to 24 inches. More typical saddle
sizes have outer diameters of 1.5 to 12 inches, optionally available in half-
inch
increments, although other outer diameter sizes can be made as desired.
Example
lengths are 8 or 12 inches
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An interior channel 42 extends through the interior 44 of saddle 30 along
channel axis C. In use, the interior diameter of channel 42 is sized to
receive and
engage an outer diameter of a corresponding pipe or insulated pipe.
Partial ribs 50 are defined on the lower face 38 of saddle 30. Ribs 50
typically have an arcuate bend corresponding in shape to the arcuate curve of
lower
face 38. Partial ribs 50 are generally transverse to the length L of saddle 30
and
parallel to the width W. Ribs 50 preferably extend a sufficient height and
width to
inhibit saddle 30 from moving relative to the lower bracket 24 of hanger 20
once
installed. Ribs 50 are preferably primarily oriented on lower face 38 and do
not
substantially extend to side portions 39. In certain preferred embodiments,
the
arcuate bend of ribs 50 is approximately 60 or less.
Ribs 50 each include a central peak section 52 and opposing slanted or
curved sides extending from face 38 to peak 52. Peak section 52 may be sharp,
blunted or rounded. Ends 56 of the ribs may be sharply defined, but preferably
are
tapered into saddle 30 at each end to form a closed end. Ribs 50 could be
mounted
to lower face 38 with an attachment process, but preferably are formed into
the
metal.
In one method of manufacture, a piece or "blank" of metal sheet either to
be bent or pre-bent into a saddle is placed into a stamping machine which
receives
the piece. The stamping machine compresses the sheet between mating portions.
During the compression, one piece of the press includes protruding partial
ribs
which stamp corresponding rib sections into the saddle. Optionally, the sheet
is
bent into an arcuate shape in the same step.
In an alternate method of manufacture, partially ribbed saddles can be made
using a roll bending process using, for example, an Acrotech Model 1618 roll
bending machine. A die 130 usable in a roll bending machine 400 (FIG. 12) is
illustrated in FIGS. 8 and 9.
Die 130 includes opposing ends 131 which are engaged and driven by the
roll bending machine. A central portion of the die has a length LD
corresponding
to the length of the saddle piece to be formed. The central portion has
opposing
ends 133 and 134 along length LD to form corresponding ends in the saddle.
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Optionally, ends 133 and 134 are flared 135 on the die to impart a flare to
the end
portions of the saddle.
In the embodiment of Figs. 8 & 9, die 130 is a solid cylinder which can be
mounted at opposing ends to a roll bending machine to be driven. In an
alternate
embodiment shown in Fig. 10, die 230 is a two piece die with an outer sleeve
235
surrounding an inner cylinder 240. Inner cylinder 240 has opposing ends which
are mountable to a roll bending machine. The outer diameter of inner cylinder
240
preferably forms a close fit with the inner diameter of outer sleeve 235 such
that
rotation of the inner cylinder by the machine transmits a corresponding
rotation to
outer sleeve 235.
In a still further embodiment illustrated in Fig. 11, die 330 includes an
outer
sleeve 335 with an outer and inner diameter and an inner roller 340. Inner
roller
includes a mandrel shaft 344 with opposing ends mountable to a be driven by
roll
bending machine. Two bearing rollers 348 are mounted to shaft 344 and engage
channels 337 defined adjacent opposing ends on the inner diameter of outer
sleeve
335. As inner roller 340 is turned, it causes sleeve 335 to rotate at a rate
proportional to the ratio between the channel diameter CD and the diameter RD
of
bearing rollers 348.
The die diameter is preferably sized to the diameter of a desired arcuate
saddle, with different sizes usable for different sized saddles. By way of
example
only, a solid die, such as die 130, can be used for saddles up to
approximately four
(4) inches in diameter. A two-piece die with an inner cylinder, such as die
230,
may be preferred for saddles from approximately four (4) inches in diameter to
five
(5) inches in diameter. A two-piece die with an inner shaft driving a sleeve,
such
as die 330, may be preferred for saddles with a diameter of approximately five
(5)
inches or larger.
The outer surface of the die defines partial ribs which press corresponding
rib portions into the saddle during the roll bending process. For example, in
dies
130, 230 and 330 the partial ribs are 150, 250 and 350 respectively. The ribs
of die
130 are described in detail, with ribs 250 and 350 being similar yet
appropriately
sized to the corresponding die diameter. As shown in detail in FIG. 9, ribs
150
preferably include a transverse length with a peak 152 and opposing side
portions
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154. The ends of the partial ribs 156 are preferably tapered into the curve of
die
130. Partial ribs 150 are preferably formed on a face of die 130 to correspond
in
placement to a lower portion of saddle 30, with blank portions on opposing
sides of
the ribs on die 130 to form corresponding non-ribbed side portions in the
saddle.
A portion of an example roll bending machine 400 is shown in FIG. 12. To
form a piece of sheet metal into an arcuate saddle, a blank piece is
preferably fed
between two rollers, one of which is die 130, with the length placed to
correspond
to the central portion of the die. Preferably the die is arranged and timed to
rotate
and form the partial ribs in the lower face of the arcuate saddle while
bending each
saddle. One method of arranging such timing is to start the die at a specific
rotational point relative to the introduction of each blank sheet to form a
saddle.
An alternate method uses an automated or timed feeding mechanism to introduce
blanks only at specified points relative to the rotation of die 130 while the
die is in
continuous rotation.
In certain embodiments, for example those shown in Figs. 13 and 14, a roll
bending machine incorporates a sensor to consistently start the die at a
specific
rotational point relative to the introduction of each blank sheet to form a
saddle.
The sensor can be mechanical, such as a cam, wheel or lever, or electrical
such as a
light sensor or an electrical circuit.
In one embodiment, illustrated with die 130 in Fig. 13, a cam 170 is
mounted to an end of die 130. A lever 175 is eccentrically pivotally mounted
to
cam 170 offset from the die axis, and extends through a bracket 177 towards a
two-
position switch 180. Lever 175 is pulled and pushed through bracket 177 during
rotation of die 130. In use, a saddle blank is arranged at a feed point into
the roll
bending die with lever 175 at its extended position relative to switch 180.
The
switch is then activated, for example by pushing handle 184 inward to push
switch
180 to engage the roll bending machine to feed and bend the saddle blank into
an
arcuate saddle with rib portions while simultaneously pulling and then pushing
lever 175 during the rotation cycle. When the die has made one complete
revolution, lever 175 returns to its extended position and pushes switch 180
outward to disengage the rolling process. Preferably, at the end stopping
point of
the die rotation the protruding ribs on the die are positioned to be
synchronized
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with the desired rib placement for when the next saddle blank is fed into the
machine.
In an alternate embodiment, illustrated on die 230 in Fig. 14 yet usable in
various die sizes, a registry point is defined on the die, and a sensor
disengages the
rolling process when the registry point reaches a desired position. In the
example
illustrated, die 230 includes a hole or depression 250 adjacent an end, for
example
on the exterior face or shoulder of sleeve or on an end face of the sleeve. A
sensor
450 is arranged to detect when the hole or depression reaches a desired
registry
point. In one example, sensor 450 is a spring-biased wheel 452 mounted on a
stalk
455 extending from machine 400. In use, the process is engaged with a manual
switch or sensor when a blank is in place or with an automated feed process.
The
wheel 452 is pushed outward by the die face during rotation of the die, and is
biased to move slightly inward to engage the hole or depression when aligned
with
the registry point. The slight inward movement of wheel 452 preferably
disengages the rolling process. Preferably, at the end stopping point of the
die
rotation the protruding ribs on the die are positioned to be synchronized with
the
desired rib placement for when the next saddle blank is fed into the machine.
The scope of the claims should not be limited by the preferred embodiments
set forth above, but should be given the broadest interpretation consistent
with the
description as a whole.
