Apparatus and method for roll forming and marking sheet metal

Apparatus for roll-forming sheet metal into air duct pipe having a predetermined part size, comprising:

• a pair of opposing and substantially parallel roller support frames spaced from one another;
• a plurality of first shafts rotatably mounted to and along each of the opposing roller support frames, the plurality of first shafts extending inwardly from each of the opposing roller support frames towards the opposite roller support frame;
• a plurality of second shafts rotatably mounted to and along each of the opposing roller support frames, the plurality of second shafts extending inwardly from each of the opposing roller support frames towards the opposite roller support frame, each of the plurality of second shafts positioned juxtapositional to a corresponding first shaft;
• a plurality of first forming rollers mounted on corresponding first shafts;
• a plurality of second forming rollers mounted on corresponding second shafts, each first forming roller being positioned juxtapositional to a corresponding second forming roller so that there is a nip between each of the juxtaposed first and second forming rollers, the juxtaposed first and second forming rollers forming a pair of opposing roll forming lines;
• a first embossing roller mounted on one of said first shafts and extending inwardly from the first forming roller mounted on the one of said first shafts to a substantially exposed forward end, the first embossing roller being separate from the first forming roller mounted on the one of said first shafts, the first embossing roller extending beyond each of the first forming rollers in the associated roll forming line towards the opposing roll forming line, the first embossing roller having an outer surface and a relief pattern extending outwardly therefrom, the relief pattern including an indication of the predetermined part size of the air duct pipe;
• a second embossing roller mounted on the second shaft positioned juxtapositional to the one of said first shafts on which the first embossing roller is mounted, the second embossing roller extending inwardly from the second forming roller mounted on the associated second shaft to a substantially exposed forward end, the second embossing roller being separate from the second forming roller on the associated second shaft, the second embossing roller extending beyond each of the second forming rollers in the associated roll forming line towards the opposing roll forming line, the first and second embossing rollers juxtaposed so that there is a nip therebetween, the second embossing roller having an outer surface which has an engraved pattern for receiving the relief pattern, the engraved pattern being substantially identical to the relief pattern;
• and
• means for rotating the first and second shafts so as to draw the sheet metal through the nips between the first and second forming rollers and the first and second embossing rollers,
• whereby the sheet metal is simultaneously roll formed into air duct pipe by the first and second forming rollers and embossed with the identifying relief pattern by the first and second embossing rollers.