# US 11,035,501 B2 · Insulated duct with air gap and method of use > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,035,501 B2 - Document ID: US11035501B2 - Status: Granted - Kind: B2 - Application number: 16/430,554 - Filed: 2019-06-04 - Published: 2019-09-19 - Granted: 2021-06-15 - Earliest claimed: 2015-11-23 - Assignees: Flexible Technologies, Inc. - Applicants: Flexible Technologies, Inc. - Inventors: Ronald L. Carlay, II; John Cullen Schlageter; Donald B. Campbell - Web page: https://patentgrep.com/patent/US11035501B2 ## CPC - F16L 11/081: {comprising one or more layers of a helically wound cord or wire (in combination with braided layers F16L11/088)} - F16L 11/02: made of fibres or threads, e.g. of textile - F16L 11/12: with arrangements for particular purposes, e.g. specially profiled, with protecting layer, heated, electrically conducting (F16L11/11 takes precedence) - F16L 59/153: for flexible pipes - F24F 13/0218: {Flexible soft ducts, e.g. ducts made of permeable textiles} - F24F 13/0263: {Insulation for air ducts} - F16L: PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL - F24F: AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING (removing dirt or fumes from areas where they are produced B08B15/00; vertical ducts for carrying away waste gases from buildings E04F17/02; tops for chimneys or ventilating shafts, terminals for flues F23L17/02) ## Abstract A flexible air duct contains a uniformly-spaced reflective insulation system, with or without bulk insulation, a liner, and an outer jacket that would allow a reduced amount or no amount of bulk insulation to be used to obtain a desired R-value insulation. The flexible air duct can be used to move conditioned air to one or more desired locations. ## Claims ### Claim 1 An insulated flexible duct comprising: a liner; a reflective insulation system surrounding the liner, and at least one jacket surrounding the reflective insulation system, the reflective insulation system further comprising: at least one low emissivity reflective surface; and at least one spacer system positioned between the liner and the jacket, the spacer system creating a generally uniform air gap between an outer surface of the liner and the inner surface of the jacket to create additional R value for the flexible insulated duct, wherein the spacer system further comprises a star-shaped spiral helix positioned between the outer surface of the liner and the inner surface of the at least one jacket to create the generally uniform air gap between the outer surface of the liner and the inner surface of the at least one jacket. ### Claim 2 (depends on 1) The flexible insulated duct of claim 1, wherein at least one bulk insulating layer is positioned between: an outer periphery of the at least one spacer system and the inner surface of the jacket such that the generally uniform air gap is created between the outer surface of the liner and an inner surface of the at least one bulk insulating layer; or an outer periphery of the liner and an inner periphery of at least one spacer system such that the generally uniform air gap is created between an outer surface of the at least one bulk insulating layer and an inner surface of the at least one jacket. ### Claim 3 (depends on 2) The flexible insulated duct of claim 2, further comprising a plurality of the at least one spacer system and the at least one bulk insulating layers arranged to create a plurality of generally uniform air gaps. ### Claim 4 (depends on 1) The flexible insulated duct of claim 1, further comprising a plurality of the at least one spacer system and the at least one jacket arranged to create a plurality of generally uniform air gaps. ### Claim 5 (depends on 1) The flexible insulated duct of claim 1, wherein the at least one spacer system is unattached to the liner or the at least one jacket. ### Claim 6 (depends on 1) The flexible insulated duct of claim 1, wherein the jacket further comprises either two layers of polyester film that are adhered together, the two layers encapsulating a scrim blanket therebetween or a continuous tube of polyethylene material. ### Claim 7 (depends on 1) The flexible insulated duct of claim 1, wherein the at least one low emissivity surface is on either an inner surface of the at least one jacket or the outer surface of the liner. ### Claim 8 (depends on 1) In a method of supplying conditioned air to a space using a flexible insulated duct, the improvement comprising using the duct of claim 1. ### Claim 9 An insulated flexible duct comprising: a liner; a reflective insulation system surrounding the liner, and at least one jacket surrounding the reflective insulation system, the reflective insulation system further comprising: at least one low emissivity reflective surface; and at least one spacer system positioned between the liner and the jacket, the spacer system creating a generally uniform air gap between an outer surface of the liner and the inner surface of the jacket to create additional R value for the flexible insulated duct, wherein the spacer system further comprises a plurality of spaced-apart staves, each spaced-apart stave extending from the outer surface of the liner to create the generally uniform air gap between the outer surface of the liner and the inner surface of the at least one jacket. ### Claim 10 (depends on 9) The flexible insulated duct of claim 9, wherein each of the spaced apart staves are attached at one end thereof to the outer surface of liner such that when the liner is expanded, free ends of the spaced apart staves extend away from the outer surface of the liner to create the generally uniform air gap and when the liner is compressed, ends of the spaced apart move toward the outer surface of the liner. ### Claim 11 (depends on 9) In a method of supplying conditioned air to a space using a flexible insulated duct, the improvement comprising using the duct of claim 9. ### Claim 12 (depends on 9) The flexible insulated duct of claim 9, wherein the jacket further comprises either two layers of polyester film that are adhered together, the two layers encapsulating a scrim blanket therebetween or a continuous tube of polyethylene material. ### Claim 13 (depends on 9) The flexible insulated duct of claim 9, wherein the at least one low emissivity surface is on either an inner surface of the at least one jacket or the outer surface of the liner. ### Claim 14 (depends on 9) The flexible insulated duct of claim 9, wherein at least one bulk insulating layer is positioned between: an outer periphery of the at least one spacer system and the inner surface of the jacket such that the generally uniform air gap is created between the outer surface of the liner and an inner surface of the at least one bulk insulating layer; or an outer periphery of the liner and an inner periphery of at least one spacer system such that the generally uniform air gap is created between an outer surface of the at least one bulk insulating layer and an inner surface of the at least one jacket. ### Claim 15 (depends on 14) The flexible insulated duct of claim 14, further comprising a plurality of the at least one spacer system and the at least one bulk insulating layers arranged to create a plurality of generally uniform air gaps. ### Claim 16 (depends on 9) The flexible insulated duct of claim 9, further comprising a plurality of the at least one spacer system and the at least one jacket arranged to create a plurality of generally uniform air gaps. ### Claim 17 An insulated flexible duct comprising: a liner; a reflective insulation system surrounding the liner, and at least one jacket surrounding the reflective insulation system, the reflective insulation system further comprising: at least one low emissivity reflective surface; and at least one spacer system positioned between the liner and the jacket, the spacer system creating a generally uniform air gap between an outer surface of the liner and the inner surface of the jacket to create additional R value for the flexible insulated duct, wherein the spacer system further comprises: a lattice cord and post blanket surrounding the outer surface of the liner, tensioning of the lattice cord of the lattice cord and post blanket causing posts of the lattice cord and post blanket to orient in a generally perpendicular direction with respect to the outer surface of the liner to create the generally uniform air gap between the outer surface of the liner and the inner surface of the at least one jacket. ### Claim 18 (depends on 17) In a method of supplying conditioned air to a space using a flexible insulated duct, the improvement comprising using the duct of claim 17. ### Claim 19 (depends on 17) The flexible insulated duct of claim 17, wherein the jacket further comprises either two layers of polyester film that are adhered together, the two layers encapsulating a scrim blanket therebetween or a continuous tube of polyethylene material. ### Claim 20 (depends on 17) The flexible insulated duct of claim 17, wherein the at least one low emissivity surface is on either an inner surface of the at least one jacket or the outer surface of the liner. ### Claim 21 (depends on 17) The flexible insulated duct of claim 17, wherein at least one bulk insulating layer is positioned between: an outer periphery of the at least one spacer system and the inner surface of the jacket such that the generally uniform air gap is created between the outer surface of the liner and an inner surface of the at least one bulk insulating layer; or an outer periphery of the liner and an inner periphery of at least one spacer system such that the generally uniform air gap is created between an outer surface of the at least one bulk insulating layer and an inner surface of the at least one jacket. ### Claim 22 (depends on 21) The flexible insulated duct of claim 21, further comprising a plurality of the at least one spacer system and the at least one bulk insulating layers arranged to create a plurality of generally uniform air gaps. ### Claim 23 (depends on 17) The flexible insulated duct of claim 17, further comprising a plurality of the at least one spacer system and the at least one jacket arranged to create a plurality of generally uniform air gaps. ### Claim 24 An insulated flexible duct comprising: a liner; a reflective insulation system surrounding the liner, and at least one jacket surrounding the reflective insulation system, the reflective insulation system further comprising: at least one low emissivity reflective surface; and at least one spacer system positioned between the liner and the jacket, the spacer system creating a generally uniform air gap between an outer surface of the liner and the inner surface of the jacket to create additional R value for the flexible insulated duct, wherein the liner comprises a pair of polymer films, one polymer film forming an inner surface of the liner and the other polymer film forming the outside surface of the liner and, optionally a helical member disposed between the polymer films. ### Claim 25 (depends on 24) In a method of supplying conditioned air to a space using a flexible insulated duct, the improvement comprising using the duct of claim 24. ### Claim 26 (depends on 24) The flexible insulated duct of claim 24, wherein the jacket further comprises either two layers of polyester film that are adhered together, the two layers encapsulating a scrim blanket therebetween or a continuous tube of polyethylene material. ### Claim 27 (depends on 24) The flexible insulated duct of claim 24, wherein the at least one low emissivity surface is on either an inner surface of the at least one jacket or the outer surface of the liner. ### Claim 28 (depends on 24) The flexible insulated duct of claim 24, wherein at least one bulk insulating layer is positioned between: an outer periphery of the at least one spacer system and the inner surface of the jacket such that the generally uniform air gap is created between the outer surface of the liner and an inner surface of the at least one bulk insulating layer; or an outer periphery of the liner and an inner periphery of at least one spacer system such that the generally uniform air gap is created between an outer surface of the at least one bulk insulating layer and an inner surface of the at least one jacket. ### Claim 29 (depends on 28) The flexible insulated duct of claim 28, further comprising a plurality of the at least one spacer system and the at least one bulk insulating layers arranged to create a plurality of generally uniform air gaps. ### Claim 30 (depends on 24) The flexible insulated duct of claim 24, further comprising a plurality of the at least one spacer system and the at least one jacket arranged to create a plurality of generally uniform air gaps.