Air duct made from sheet metal stamping

A sheet metal stamping forming an air duct for use in heating and cooling systems and the like. The stamping has a generally rectangular shaped body portion and a protruding tongue portion extending from at least one side thereof. The stamping is foldable along its end edges and the tongue portion whereby two such stampings may be cooperatively engageable with a pair of side panels to form an air duct section having an inlet, outlet and a diverter or secondary outlet formed by the tongue portions. The tongue portions are adapted for connection to standard conventional take-off fittings.

Sheet metal duct section having an inlet and outlet comprising in combination:a prestamped upper and lower spaced panel interconnected by spaced side panels, at least one side panel being shorter in length than said upper and lower panels and defining an opening through which at least a portion of flow through said inlet isdiverted, said upper and lower panels having end edges and a central body portion extending the length and width of said duct section from said inlet to said outlet and formed tongue portions extending laterally beyond said shortened side, said stampingsbeing folded along their end edges and cooperatively engaged with said side panels to form the air duct section, and said tongue portions cooperatively forming a diverter outlet to divert flow through said inlet from said outlet, said duct having adiminishing cross section from said inlet to said outlet.

The prior art has recognized the advantages of a main conduit or trunk duct having reductions in cross sectional area along its length to provide generally equal air flow at each outlet. Such systems are however, relatively expensive andaccordingly have not found commercial acceptance. Partially prefabricated air duct fittings have been proposed for use in heating and ventilating systems, however, in each case a great number of separate component parts are required including top andbottom panels, take-off sections, side panels and the like. In some of prior art systems the top and bottom panels and the side walls are provided with spaced longitudinally extending marginal tabs and corresponding slots. The tabs, when inserted inthe slots are bent over to secure the plate and wall together in a rigid assembly. Such systems, however, require careful handling since the tabs are easily deformed during such handling. Additionally, if an ar tight seal is required, the tabs and slotmust be sealed with putty, or similar sealing substances.

In another system known in the prior art, prefabricated assembled components of the duct system are provided. Each component is reduced in cross sectional size from the previous adjacent component whereby they may be nested for shipment andstorage. In the above systems, however, separate provision must be made for the connection of take-off ducts and other fittings to registers or wall stacks or the like. In these cases either elaborate tab and slot combinations must be prefabricated orotherwise provided or in the case of the nestable preassembly an opening must be cut in the duct work in each position where it is desired to connect the take-off section.

While the above described systems are known in the art, it yet remains necessary to provide a totally standardized system which is readily assembled, relatively inexpensive and which utilizes standardized parts. The system of the presentinvention is designed for the least restriction of air from the heating or cooling system through the main ducts and into the take-off or leader pipes. A generally standard shaped fitting based on a modular construction concept is provided having astandard length and a variable width based on a preestablished range of sizes. A single fitting which provides top and bottom plates of a duct system is adapted for utilization with side panels and includes at least one outwardly extending tongue memberthereon forming a diverter or take-off section on which any of a large number of standard take-off fittings may be attached. Since the system is based on a standard length for each preformed fitting, layout is considerably simplified, and in fact quickand relatively accurate calculations to determine the total length of the system may readily be made simply by counting as for example, in a residential building, the number of floor joists to lay out the entire system. In the preferred embodiment ofthe invention, each panel section is fabricated from a stamping and has a lip or other fastening means formed at the ends and edges thereof. Each section has a standard length of 16 inches or multiples thereof which correspond to the conventionalspacing between floor joists.

The standardized system of the present invention is applicable to generally all heating installations and specifically adapted for home heating situations. The expense of custom-made installations is reduced. Each section formed in accordancewith the present invention has an inlet side and a diminished outlet side thereby providing, when assembled, a heating system in which the main trunk line is decreased at each take-off junction to thus proportion and reduce the cross sectional area ofthe main trunk line along its length.

Basically, the invention provides a sheet metal duct section having an inlet and an outlet and includes prestamped upper and lower spaced panels interconnected by spaced side panels. At least one side panel is shorter in length than the upperand lower panels thereby defining an opening through which at least a portion of the flow of air through the inlet portion is diverted. The upper and lower panels are prestamped and have a central body portion extending the length and width of the ductfrom the inlet to the outlet and a tongue portion is formed thereon extending laterally beyond the shortened side. The tongue portion is folded for connection to a diverter or take-off duct section. Finally, a secondary side panel joins the tongueportions to form the diverter duct.

The many advantages of the present metal stamping invention will become apparent to those skilled in the art upon reading the following description with reference to the accompanying drawings illustrating the preferred embodiment of the invention.

Reconfigurable variable blank-holder force system and method for sheet metal stamping

A reconfigurable variable blank-holder force system (and method) for producing sheet metal stamping comprises a portable hydraulic unit, controlled by a digital control system and a knowledge-based expert system to enable reconfigurability and an easy transition from the try-out stage to production.

The knowledge-base has a hierarchical structure and includes stored information about part geometry, material properties and press parameters. The expert system enables an operator to determine optimal blank-holder forces, and to fine-tune through a graphical interface unit. The optimal blank-holder forces are generated by hydraulic force actuators, using a controller running a nonlinear algorithm that accounts for valve nonlinearities, variable flow-rate and numbers of operational cylinders.

The portable hydraulic unit preferably comprises hydraulic cylinders with quick disconnect hoses, a manifold, servo-valves and a pump unit. A structured method to utilize this system to produce sheet metal stampings is also described. An article embodying the method is included.

Method of achieving reconfigurability in a blank-holder variable force system for producing stampings from sheet metal blanks, comprising: using movableblank-holder force actuators and variable blank-holder forces to hold and support said sheet metal blank at a first set of blank-holder force actuator locations; monitoring a first set of parameters selectively including punch force, blank-holder forceactuator numbers and locations, and blank-holder force magnitudes at said movable blank-holder force actuators; inspecting a sheet metal stamping work piece produced using said first set of parameters; noting differences between characteristics of asample work piece fabricated using said first set of parameters, and requirements of an acceptable sheet metal stamping work piece; and, using said differences and knowledge-based inputs from an expert system to arrive at a second set of newreconfigurable parameters.

A variable blank-holder force system for performing sheet metal stamping operations, comprising: movable blank-holder force actuators to hold and support said sheet metal stamping at a first set of locations; sensors associated with saidmovable blank-holder force actuators for monitoring parameters associated with the blank-holder force actuators including blank-holder force actuator locations and force magnitudes at the blank-holder force actuator locations; a user interface forviewing and using a first set of parameters for a trial run and for recording differences between a stamped sheet metal from a trial run compared with requirements in an acceptable stamped sheet metal work piece; and, a controllable arrangement forarriving at a second set of parameters based on said differences, knowledge-based software controlled by an expert system and knowledge-based hierarchy.

Sheet metal stamping is an indispensable and significant process because it is well suited to mass production of a wide variety of parts. In the automotive industry, it is used to make several body parts such as doors, hoods and lift-gates. Several other industries such as the consumer appliance industry and the aerospace industry use sheet metal stamping extensively. It is highly desirable to ensure high quality standards for sheet metal stampings so as to avoid problems during subsequentassembly stages and to ensure that the form and finish meet requirements.

A publication by Ananthakrishnan S., Agrawal S., Venugopal R., and Demeri M., entitled "RCS Based Hardware-in-the-loop Intelligent System Design and Performance Measurement," inProceedings of PerMIS 2002, NIST, Gaithersburg, Md., 2002, teaches design of an intelligent system with applications to manufacturing, based on a Real Time Control System (RCS) architecture. The Ananthakrishnan publication describes case studies on howthe RCS architecture can be used in a flexible automation scenario, where traditional industrial control cards (hardware) do not provide adequate measures of performance.

In addition, certain tooling concepts and blank-holder force actuator controlunits with individually controlled hydraulic cylinders have been developed to allow local control of metal flow into the die cavity during a stamping operation. Forces are applied on the sheet metal blank using hydraulic cylinders which are mounted onthe lower bolster of a hydraulic press.

In the known type of hydraulic or mechanical press, a ram depresses the piston of each of the hydraulic cylinders via the blank and tooling in a blank-holder force actuator area to raise the pressure inside thecylinders. The pressure is transferred to the blank. A closed-loop control system modulates the flow of hydraulic fluid from the cylinder. In known arrangements, pressure within the cylinder is difficult to control using commercially available PID(Proportional-Integral-Derivative) control cards.

The few systems that are available presently are systems of hydraulic cylinders installed in the bed of the press (under the die). The hydraulic cylinders used to provide force actuation in knownsystems are placed in fixed locations in the bed of one particular press, and the force actuators are configured for operation in that press. In essence, these systems are not flexible and are customized for one particular press and thus tend to be veryexpensive.

The production of sheet metal stamping parts involves two distinct phases, namely, try-out and production. In the try-out phase, the die design is validated, and required process parameters (blank-holder force actuator forces, punch force etc.)are determined. Try-out is conducted by attempting to make the part and modifying the die and process parameters, until a part is consistently made within the required design tolerances. After successful try-out, the final die design and processparameters are transferred to a production unit that mass produces the part. In practice, try-out and production are typically conducted by different companies in different locations.

It is desirable to provide a system and method for sheet metal stamping that would offer reconfigurability utilizing a knowledge-base, as well as the most economy and flexibility in design, and in doing so, address the needs of both try-out andproduction.

Clean out your shower drain without chemicals

The bathroom smells like a dead rat. You know it's the shower drain telling you it needs to be cleaned out again. Don't go for the caustic, harsh chemicals! Go green, instead.

The smell is absolutely nasty. An accumulation of rotting hair and grease from soap can clog up your drain and emit a putrid, rotten egg odor into the room. Don't call a costly plumber. Most likely, you can clean out that shower drain yourself…and WITHOUT chemicals.

Why go green

The fumes from chemical drain cleaners are toxic and harmful to children, pets and adults. They're not good for the environment, either. In addition, the chemicals can damage metal pipes. If this isn't enough, the high price of these cleaning products should also be considered.

How to clean out the shower drain

Warning: This is NOT a job you want to do in your best clothes or on a queasy stomach! Have the following supplies handy:

Metal coal hanger

Plastic grocery bag (without holes)

Rubber gloves

3/4 cup baking soda

1/2 cup of white distilled vinegar

A large, old rag

A pot of boiling water

1.Remove the shower drain cover, being careful not to drop any screws down the drain. Using rubber gloves, clean the drain cover of any accumulated hair.

2.Bend a metal coat hanger so that the hanger portion forms a hook. Use this to fish out any clumps of slimy hair that might be clogging the shower drain. Have an old plastic grocery bag handy to catch the mess. Quickly tie the bag shut to contain the odor.

3.Have the baking soda, vinegar and rag ready at hand.

4.Pour the baking soda down the shower drain.

5.Pour the vinegar down the drain right after.

6.Immediately plug the shower drain with the rag. The baking soda and vinegar will react together to form a bubbling brew that the rag will help contain.

7.Wait twenty minutes. Use this time to bring a pot of water to a boil.

8.Remove the rag and slowly pour all the boiling water down the drain.

9.Run clear water from the shower to test if the drain is running clear. If not, repeat the process.

10.Open the window and air out your bathroom.

11.You may need to repeat the process the next day if the odor persists.

If this attempt to clean out the shower drain has failed and the odor still fills the room, the clog may be further down the pipe requiring the use of a sewer snake. If this totally grosses you out, it might be time to call in the plumber. This "Go green" method of cleaning out the shower drain, however, usually does the trick, so it's worth a try.

Metal Stamping Materials and Processes

Little is known about this process, what type of machinery it uses or how it benefits our lives. The truth is simple. The process of metal stamping and the products it produces are virtually unlimited. Today, this process helps your car operate, medical equipment function and supplements other key components of our daily life.

Metal stamping operations utilize leading precision stamping presses including Bruderer, Kyori, Ingyu, and Minster with sizes ranging from 5 tons - 220 tons. Materials used in the process include Beryllium Copper, Phosphorous Bronze, Stainless Steel & Copper and Cold Rolled Steel with thickness ranging from 0.002" to 0.180". As a result, manufacturers have the capability to provide services and products for a wide variety of industries.

The Metal Stamping Process is put to use for a number if industries, including:

* Automotive parts stamping

* Medical stamping

* Stamping for mobile devices

* Stamped and drawn shields for industrial and electronics industries

* Bandolier

* Bandolier wire

* Header pins

* Contact pins

* Terminals

* Sleeved terminals

* Reel to reel

* Precision miniature stamping

* High speed

* Micro

* Stainless steel

* Medical Stamping

In addition, several types of metals are used in the process, including:

* Aluminum

* Beryllium

* Brass

* Bronze

* Cold Rolled Steel

* Copper

* Mylar

* Phenolic

* Stainless Steel

* Teflon

* Titanium and more!

The process of bandoliering involves the use of a delivery member (a "band", or "carrier") that conveys components from one point to another. In the precision metal stamping arena, bandoliering has been used extensively for manufacturing components such as pins assembled into electronic connectors. Bandoliered components are formed by a special type of precision metal stamping die (referred to as a progressive bandolier die), which is operated in a mechanical press (typically 60 ton, or greater). Raw material in the form of wire (ferrous or nonferrous) is fed into the die to be formed (stamped) into the final desired component, and raw material in the form of strip is introduced into the die to be formed into the bandolier to carry the final component. This article expounds on the use of the bandoliering technique for manufacturing various types of precision metal components. Specifically, the following will be discussed: (1) the benefits of bandoliered components, (2) examples of various applications that can employ bandoliering, and (3) various manufacturing options that can be incorporated into this process.

First, the benefits of producing a precision metal component in a bandoliered configuration (mainly for high volume applications) are threefold: (a) reduced unit cost, (b) repeatable quality, and (c) in-line post-processing. Unit cost can be reduced due to the fact that the stamping operation is performed in a progressive precision metal stamping die, and also because of the fact that the bandoliering process allows for time-saving secondary operations (such as assembly), which reduce overall unit cost. Quality is inherently repeatable in a progressive stamping die. The most significant benefit of the bandoliering process is related to the fact that the stamped components all exit the die in an "ordered" configuration, ready for an assembly process (either manual or automated) or for other secondary operations while still on the band (carrier). Related to this benefit is the fact that this process also lends itself to other manufacturing operations that can be performed inside the die (discussed later).

Second, the types of applications for which bandoliering may be employed are numerous. The following are examples of various industries that could employ this process: Medical devices (e.g., surgical components), Orthopedic components (e.g., pins), Electronic connectors (e.g., connector pins), Military components, as well as many other industries/applications.

Lastly, a bandoliered process can provide for various manufacturing operations to be performed either inside the precision metal stamping die, or outside of the stamping die (while the components are still located on the bandolier). Some examples of in-die operations that can be performed include: coining, sharpening, machining, assembly, and welding. Examples of secondary operations performed outside of the die (while the precision formed components are still on the band) include: cleaning, coating, heat-treating, and automated assembly.

High volume applications for stamped metal components should be evaluated to see if a bandoliered application could be used, especially if the need is present for secondary operations such as assembly, or other operations as discussed above.

The parts manufactured during the metal stamping process vary from tiny parts in material as thin as .05mm to larger frames and heavy duty metal components. Precision presses vary in size from 5 tons to 220 tons, and with speeds up to 1,500 per minute. Stamping services also have skiving equipment to contour metal thickness and configuration as required.

The Ultimate Shower Drain Clog Remover

Long hair and shower drain do not mix well. I found this out the hard way. I have long hair and enjoy long showers; therefore, I found myself purchasing a bottle of drain de-clogger at least once a month or so. I tried liquids, gels, foams, every product and brand available, it seemed. Nothing worked for long, even those most expensive products with MAXIMUM STRENGTH or PROFESSIONAL FORMULA splashed across the label on the bottle.

I'd find myself showering in ankle-deep water after just a few minutes under the spray. Finally, I spotted a product called the Zip-It Strip at my local hardware store. Desperate for anything to help me solve this recurring and most annoying problem, I decided to give it a try.

The Zip-It Strip is a flexible, flattened piece of coated plastic, about eighteen inches long and about the width of a small pencil. It has a loop at one end to use as a handle and serrated teeth all along the shaft that point upward toward the handle. Following the directions on the package, I held the loop and slowly inserted the other end into my clogged drain as far as I could. I wiggled it briefly, and then began to pull it back up slowly and carefully.

A few months ago, I received the Scrubbing Bubbles Automatic Shower Cleaner, complete with shower caddy, from a marketing company to test. I practically ran to my shower to install it since cleaning the shower ranks up there with cleaning the toilet for me. I must confess, June Cleaver keeps a better house than I ever could. The idea of a set it and forget it mentality really appealed to me. Who doesn't want to save time cleaning? The instructions were very simple: push the button after your shower, pull the curtain shut, and let the Scrubbing Bubbles Automatic Shower Cleaner do all of the work for you. A housewife's dream come true!

The dream come true turned out to be dream gone bust. The Automatic Shower cleaner did not work as promised. Instead, it left a gritty, white residue on my shower walls, not to mention my shampoo bottles! Upon a cursory glance, the shower appeared clean with no sign of mold or rust stains. The white, gritty residue was not noticeable on the white walls unless you inspected closely and actually did a touch test. Unfortunately, the residue also adhered to the metal spigot and drain, leaving unsightly water marks. While I did save time "cleaning" my shower, it really wasn't clean.

I decided to try Mean Green Bath, Tub & Tile Cleaner to see if it would be able to remove Shower Cleaner build up and return my shower to the smooth finish that it had before I began using the Scrubbing Bubbles product. The product instructions directed me to spray the shower, let it sit and work for 3 minutes, and then wipe it off. I sprayed my entire shower, fixtures and all, and waited three minutes before returning to clean it with a damp cloth.

The serrated teeth did their job well, and out came a hamster-sized wad of hair and slimy gunk! I threw the mess in the waste can and re-inserted the tool in my drain. This time the mess that came out was considerably smaller and less slimy. After three insertions, no more hair came out of the drain. Cleanup was very easy; I just squirted a little bit of liquid soap on the strip and held it under running hot water until all traces of gunk were gone.

Since then, I have had NO more problems with the shower drain clogging! I use the Zip-It Strip once every six weeks or so in my shower and sink as preventative maintenance, and I have never had another clogged drain. This handy little gizmo that cost less than the price of one bottle of drain cleaner (it was only $2.49!) has completely solved my problem. Storing it can be something of a minor challenge, since it is too long for most bathroom drawers. I have mine hanging on a hook inside the linen closet door. It is an indispensable tool that no household should be without!

Floor and Shower Drains

We all know that any type of shower drain can get clogged, some more easily than others. Even though they are designed to withstand quite a good amount of abuse, floor and shower drains are, nevertheless, common candidates for clogging problems. Hair and other shower by-products easily get caught in subsurface pipes. Floor drains are prevalent in laundry rooms, garages, and basements where they are frequent receptacles for wastewater from washing machines, air conditioners, and water heaters. These drains are necessary, the waste has to leave your house some way, but when a clog occurs they are also some of the hardest drains to clear.

Shower Drains

Interestingly enough, the first thing you should try when unclogging your shower drain is pouring a hair removal product, Nair, for example, down the drain. Chances are hair is the reason for your clog and there's a good chance this will work. If it becomes a recurring problem, you may need a better shower drain cover to catch more of the hair before it enters your drain. If you don't have a hair removal product in your home, baking soda and vinegar can also work.

If this doesn't work, you may have a more extensive problem. You may need to call a plumber if you don't have the expertise to disassemble the drain. When you take this recourse, you should ask the plumber about the general condition of the shower drain, not just the clog. Newer drain assemblies use a bondable waterproof membrane that can protect your mortar bed from becoming saturated.

Floor Drains

Floor drains are a different matter altogether. More than just wastewater, lint, sand, and grime can crystallize in your drain causing a real clogging nightmare. When this happens you're way beyond hair removal products and will probably need to either call a plumber or rent a power auger. This machine uses cutting blades to cut through the clog. If you have a drain basin with a clean out plug, you'll be able to circumvent the drain trap and enter directly into the pipe. Otherwise, you'll have to snake the drain through the drain assembly, which increases the difficulty in reaching the clog. Once you reach the clog, the blades are designed to alternate directions as you move back and forth through the clog.

Floor drains are unique in that they are often designed to allow a certain amount of overflow. High amounts of pressure can be created in many floor drains. A standpipe holds back some of the wastewater causing the drain to overflow. This keeps the pipes and drain assembly from breaking. If you think your drain is accepting high levels of wastewater, this can be a bigger issue than a clog. You might consider talking to a plumber about any possible risks associated with your drain assembly.

In accordance with aspects of the present invention, a shower drain assembly is provided for use with a shower base having a drain opening. The drain assembly includes a drain fitting, an annular pressure plate, and an annular collar. The drain fitting has an upper lateral flange and an upright cylindrical portion extending downward from the underside of the flange. The cylindrical portion includes a number of rigid shelves extending laterally thereabout, with upright spaces being available between shelves.

The annular collar has an inner diameter with a number of ribs extending laterally inward from the inner diameter surface. The collar also includes a number of holes adapted to engage fasteners. During use, the drain fitting is inserted downward through the drain hole and is stopped by the flange. The pressure plate and collar are slipped upward around the drain fitting cylindrical portion, with the ribs passing through the cylindrical portion spaces. The collar is rotated so that the bottom of the ribs rest against the surface of the shelves. The fasteners are inserted into the holes and made to create an upward force on the pressure plate and a downward force on the collar. The collar ribs engage the shelves, thereby pulling the fitting downward.

In accordance with still other aspects of this invention, an improvement to a shower drain fitting having an upper lateral flange and an cylindrical portion extending downward from the underside of the flange is provided. The improvement includes a number of channels formed in the cylindrical portion exterior surfaces the channels being formed as upside down "J" shapes. The improvement further includes an annular collar having an inner diameter with a number of ribs extending laterally inward from the inner diameter surface. The collar includes a number of holes, each being adapted to engage a fastener. During use, the collar is placed about the cylindrical portion with the collar ribs being engaged in the channels.

Metal Stamping Quality Control

Metal stamping is a form of metalworking that is completed using various levels of difficulty. Almost anyone can form their own jewelry, flowers, numbers and letters out of metal using metal stamping kits or other tools. The higher the quality of the metal used, the longer these personal things will last. Metal stamping is also an industrial fabrication process used to create weaponry, vehicle components, dollar bill changers, vending machines, decorative sheet metal parts, medical life-saving devices, and many other items.

Stamping includes a variety of sheet-metal forming manufacturing processes, such as punching using a machine press or stamping press, blanking, embossing, bending, flanging, and coining. This could be a single stage operation where every stroke of the press produce the desired form on the sheet metal part, or could occur through a series of stages. The process is usually carried out on sheet metal, but can also be used on other materials, such as polystyrene.

When working with metal stamping in the industrial world, material quality is very important. A metal stamping company may work with aerospace or medical industries creating products that can save lives-if the metal used is of low quality, lives can be destroyed instead.

Stamping simulation is a technology that calculates the process of sheet metal stamping, predicting common defects such as splits, wrinkles, springback and material thinning. Also known as forming simulation, the technology is a specific application of non-linear finite element analysis. The technology has many benefits in the manufacturing industry, especially the automotive industry, where lead time to market, cost and lean manufacturing are critical to the success of a company.

Recent research by the Aberdeen research company (October 2006) found that the most effective manufacturers spend more time simulating upfront and reap the rewards towards the end of their projects.

Stamping simulation is used when a sheet metal part designer or toolmaker desires to assess the likelihood of successfully manufacturing a sheet metal part, without the expense of making a physical tool. Stamping simulation allows any sheet metal part forming process to be simulated in the virtual environment of a PC for a fraction of the expense of a physical tryout.

Results from a stamping simulation allow sheet metal part designers to assess alternative designs very quickly to optimize their part for low cost manufacture.

Quality control is important, from verifying the metal when it's received to complete testing and inspection once the product is completed. Metal stamped parts can be made into fuel injectors for an automobile, engines in an aircraft, bayonet assemblies, and navigation systems used by the military. With components that can take lives if they fail, it's important to ensure the company you're working with takes quality control very seriously.

First inspection of the material when it is received is an important quality control process. If the metal company can verify where the materials that will be used in production come from, it is likely they take care to make sure your components do not fail on you. Material identification provides documentation as to where the metal has been before being used in fabrication; it shows where it's made and how it's transferred. By using metals from reputable sources, metal stampings are more durable, smoother, and last longer than questionable materials.

Final inspection of the completed component is just as important as material identification. By performing non-destructive testing and other inspection methods on the product, any defaults or other issues will be noticed. A company with high quality standards keeps their rejected products to less than 1%. This shows that quality control is completed during every step of the fabrication process.

Metal stamping prototypes are a great way to ensure that the final fabrication of all parts will be correct in tolerance, size, durability, and design. Whether the prototype is a working part or not, working with companies who offer this as an option can mean the difference between getting exactly what you want and a completed order that doesn't match your needs.

Shower drain tool and method for installing and removing a shower drain

A shower drain tool includes a blade for engagement with the ribs on the internal surface of a shower drain. The tool also includes a stabilizer plate connected to the blade to seat the tool on the drain and prevent the tool from falling through the drain into the drain pipe. The tool further includes one of various tool adapters.

The tool adapter can be a nut to be spanned by an adjustable or open-end wrench, or a hole into which a socket wrench drive or the tip of a breaker bar or T bar can be inserted, to rotate the tool. The tool adapter can also be a pipe wrench extension so that a pipe wrench can be used to rotate the tool. Alternatively, the tool can include a device, such as a T bar, integral with the stabilizer plate to rotate the tool.

Shower drain commonly used as a drain for a shower having a tile floor, the shower drain comprising a threaded flange which is rotated onto a threaded drain pipe, the shower drain further comprising a rim, the rim being mounted to the flange with a shower pan membrane captured between the flange and the rim, the rim having an upper edge and internal ribs;a blade for engagement with the ribs of the shower drain so that the drain can be rotated by torque applied to the blade;a stabilizer plate connected to the blade to seat the tool on the upper edge of the rim of the shower drain, the diameter of the stabilizer plate being sufficient that the stabilizer plate frictionally engages the upper edge of the rim to maintain the tool seated on the drain while the tool is being rotated and to prevent the tool from falling through the drain into the drain pipe; and means coupled to the stabilizer plate for imparting rotation to the blade.

The shower drain tool as defined in claim 1 wherein the means coupled to the stabilizer plate for imparting rotation to the blade comprises a pipe wrench extension connected to the stabilizer plate, the pipe wrench extension being configured so that a pipe wrench can grip the extension and be used to rotate the tool.

Many tools have been developed for use by the construction industry. Various general purpose tools are commonplace, such as a hammer, saw, screwdriver, wrench, and numerous other tools. Certain tools have been developed or refined for particular trades, for example, roofing hammers have been developed for roofers, miter saws have been developed for finish carpenters, side cutters have been developed for electricians, and pipe wrenches have been developed for plumbers, etc. Specialized tools facilitate efficient completion of the work required to be performed by the particular tradesman.

By way of example, plumbers typically possess various tools, such as a pipe wrench, pipe cutter, breaker bar, T bar, etc. Plumbers also typically use specialized tools that enable them to more efficiently complete certain tasks, such as the installation of drain hardware.

Consequently, it would be desirable to provide a tool for removal of a commonplace shower drain used in a shower having a tile floor, such as the E-Z Test drain. It would also be desirable to provide a tool to facilitate installation of such a drain. Preferably, such a tool would be rugged in construction and inexpensive and yet provide an effective tool for removal and installation of a shower drain.

One embodiment of the present invention provides a tool to remove a shower drain commonly used as a drain for a shower having a tile floor. The shower drain tool in accordance with the present invention can also facilitate installation of the drain.

The shower drain tool in accordance with an embodiment of the present invention comprises a blade for engagement with the ribs of a shower drain so that the drain can be rotated by torque applied to the blade. The shower drain tool also comprises a stabilizer plate connected to the blade to seat the tool on the shower drain and prevent the tool from falling through the drain into the drain pipe. Additionally, the shower drain tool preferably comprises means coupled to the stabilizer plate for imparting rotation to the blade.

Metal stamping process using a wire preform

Metal parts can be economically fabricated by a metal stamping that comprises preforming a piece of wire to have a shape corresponding to the 2-dimensional configuration of a desired product workpiece, flattening the wire to form a metal blank, and subjecting the metal blank to metal stamping to obtain the desired product workpiece. The process can significantly reduce the amount of scrap material and thereby reduce manufacturing costs.

Metal parts are fabricated by a variety processes such as casting, die casting, and forging. One of the more common processes used for manufacturing metal parts is called metal stamping, which has been in use for over 150 years. Metal stamping,which in general involves taking a flat metal sheet and converting into a shaped article (i.e., a metal part) using a die and press, is a cost-effective process because it permits metal parts to be manufactured at high production rates.

In a conventional metal stamping process, a sheet of metal stock material, such as aluminum, copper, zinc, steel, stainless steel, nickel, titanium, or the like, is introduced into a stamping press such as a mechanical or hydraulic stampingpress. The stamping press has a die means and a punch means which together are used to form blanks from the initial sheet of stock material. These blanks are then subjected to further stamping procedures to form metal parts.

A disadvantage of conventional metal stamping processes is that the formation of the blanks from the initial sheet of stock material and the subsequent further processing of the blanks into metal parts can result in generation of excessiveamounts of scrap material, thereby adding to the cost of manufacture due to both loss of material and cost of waste disposal.

After the preforming stage, the shaped wire or preform is then subjected to a flattening process to achieve a "blank" from which the desired product workpiece will be obtained via a stamping process. The term "wire" as used herein is not to belimited to wires having circular cross sections. Wires of other cross sections such as square, rectangular, etc can also be used. Further, the effective diameter of the wire can vary widely depending on the desired thickness of the metal part and theflattening process. The wire can be flattened by any typical process suitable for applying the requisite pressure to a piece of metal. For example, a shaped section of wire having an effective or nominal diameter of, for example, 3 to 50 mm, preferably5 to 20 mm, can be flattened to a preformed piece of metal having a thickness of, for example, 1 to 30 mm, such as 1 to 25 mm or 8 to 30 mm, preferably 2 to 8 mm, by passage through a mechanical or hydraulic press that applies a pressure of, for example,60 to 1000 tons, preferably 100 to 600 tons. The dimensions and tonnage listed above are merely provided as examples and are not intended to limit the invention.

Thus, the width and thickness of the blank are determined by the selection of the nominal diameter of the wire and the amount of pressure imposed during the flattening process. The length of the blank is determined primarily by the performingstage, by selecting the length of the wire and it's perform shape prior to the flattening step, although the flattening step will also influence the overall length of the blank.

This procedure, in which the blank is made from a flattened preformed wire, results in considerable savings in material costs as the blank obtained from the flattened preformed wire requires far less material than a conventional blank obtainedfrom a metal sheet. In other words, in a conventional procedure blanks are cut and formed from a sheet of flat rolled metal. This procedure inherently imposes material costs due to the resultant scrap material. Yet, in the process according to theinvention, the blank is formed with little or no material loss.

After the preform is converted into a blank, the blank can then be subjected to one or more further conventional metal stamping procedures. In such procedures, the blank can, for example, be "stamped" in a die and press arrangement such as in amechanical or hydraulic press whereby excess material is trimmed from the blank to form a desired product workpiece, either a final product or an intermediate thereof. A typical metal stamping machine is a Minster.RTM. 200 ton mechanical press.