Corner seal device for ductwork for conditioned air and method of assembly of such ductwork to prevent air leaks

1. A sealing device for sealing a space defined between respective end portions of an adjacent pair of orthogonal flange members of a conditioned air duct having a generally rectangular cross-section, the sealing device comprising:

a) a substantially planar first plate member having a surface dimensioned and configured for placement in face-to-face relation with corresponding adjacent planar surface portions of said adjacent pair of orthogonal flange members, said first plate member provided with at least one attachment device for attachment of said first plate member in position with respect to said pair of orthogonal flange members and wall portions at a corner of said duct; and

b) a leg member extending away from a generally central portion of said first plate member and being generally perpendicular thereto, said leg member comprising second and third orthogonal plate members extending in respective orthogonal planes and having respectively orthogonal surface portions, said second and third orthogonal plate members configured and dimensioned to engage corresponding respective adjacent orthogonal inner wall surface portions of said duct when said first plate member is positioned on said planar surface portions of the adjacent pair of orthogonal flange members.

2. The sealing device according to claim 1 , wherein said leg member is integrally attached to said first plate member.

3. The sealing device according to claim 2 , wherein said first plate member and said leg member are monolithically formed of a material approved for heating, ventilating and air conditioning systems.

4. The sealing device according to claim 3 , when said first plate member and said leg member are made of at least one of a metal and plastic.

5. The sealing device according to claim 4 , wherein said metal is at least one of steel, galvanized steel, stainless steel and aluminum.

6. The sealing device according to claim 5 wherein said surface portions of said first plate member and said leg member, which are adapted to contact said respective adjacent pair of orthogonal flange members and said corresponding respective inner wall surface portions of said duct are coated with adhesive sealing material for attachment to said respective surface portions so as to cover and seal said space between said adjacent pair of orthogonal flange members to prevent leakage of conditioned air therethrough.

7. The sealing device according to claim 6 , wherein said adhesive sealing material is approved for heating, ventilating and air conditioning systems.

8. The sealing device according to claim 7 , wherein said first plate member is configured to define a pair of orthogonal sections dimensioned for respective face-to- face engagement with said corresponding pair of orthogonal flange members, and said second and third plate members of said leg member are configured, dimensioned and positioned for face-to-face engagement with said corresponding orthogonal inner wall surface portions of said duct adjacent said corner.

9. The sealing device according to claim 1 , wherein an angle plate member is attached to said flange members at said corner, and said at least one attachment device of said first plate member is configured and dimensioned for locking attachment to said angle plate member.

10. The sealing device according to claim 9 , wherein said attachment device is comprised of a pair of locking attachment prongs extending perpendicular to said first plate member, and configured to enter correspondingly dimensioned apertures in said angle plate member, said locking attachment prongs being configured and dimensioned to become resiliently engaged with said apertures in said angle plate member to retain said first plate member and said leg member in position with respect to said ductwork.

11. The sealing device according to claim 10 , wherein said at least one attachment device is comprised of upstanding side walls dimensioned, configured and adapted to resiliently engage the adjacent pair of orthogonal flange members of said duct to attach said first plate member and said leg member to said duct.

12. The sealing device according to claim 11 , wherein said rectangular shaped conditioned air duct has a square cross-section.

13. A sealing device for sealing flanged sections of ductwork attached together with the flanges positioned in face-to-face relation to form a continuous duct system for conducting conditioned air, said flanges being respectively oriented at right angles to each other and to the ductwork, said flanges defining at least one aperture between their end portions, which may permit leakage of conditioned air therethrough, the sealing device comprising:

a) a leg member having generally orthogonal plate members extending in respective orthogonal planes and adapted to be positioned in engagement with adjacent inner corner wall portions of the ductwork section, said leg member further having a substantially planar plate member integrally attached thereto and generally perpendicular thereto, said plate member being configured and dimensioned to be placed in face-to-face relation with respective adjacent surface portions of said flanges, said plate member including an attachment device for attachment of said plate member proximate the end portions of said flanges, said leg member and said plate member respectively provided with a soft sealing material on all surfaces coming into contact with the respective surface portions of the ductwork when inserted into the corner of the ductwork to prevent leakage of conditioned air.

14. A duct for directing conditioned air in a heating, ventilating and air conditioning type system, the duct comprising:

a) a ductwork section having duct walls and a generally rectangular cross section, each corner of said rectangular ductwork section having an adjacent pair of channel flanges extending orthogonally from the respective duct walls and orthogonally with respect to each other, wherein end portions of each adjacent pair of orthogonal channel flanges define an open space at each corner of the ductwork section;

b) an angle plate seated at each said corner of said ductwork section in said adjacent pair of orthogonal channel flanges for attaching the ductwork section to a second correspondingly rectangular ductwork section adjacent thereto, each said angle plate including two legs formed together in angular relation by an integral corner; and

c) a sealing device for respectively sealing said open space formed between said adjacent pair of orthogonal channel flanges at one of the corners of the ductwork section, said sealing device comprising:

(i) a substantially planar first plate member having a surface portion dimensioned and configured for placement in face-to-face relation with corresponding adjacent planar surface portions of said adjacent pair of orthogonal channel flanges, said first plate member provided with at least one attachment device for attachment of said first plate member in position with respect to said pair of orthogonal flanges and corresponding wall portions at the one of the corners of one of said ductwork section; and

(ii) a leg member extending away from a generally central portion of said first plate member and being generally perpendicular thereto, said leg member comprising second and third orthogonal plate members extending in respective orthogonal planes and having respective orthogonal surface portions, said second and third orthogonal plate members configured and dimensioned to engage corresponding respective adjacent orthogonal inner wall surface portions at the respective corner of said ductwork section when said first plate member is positioned on said planar surface portions of the adjacent pair of orthogonal flanges, thereby providing an airtight seal for at least a portion of said open space between said adjacent pair of orthogonal channel flanges at the respective corner of said ductwork section.

15. The duct according to claim 14 , wherein each said ductwork section has a square cross-section.

16. A heating, ventilating and air conditioning (HVAC) system which includes ductwork for conducting conditioned air therethrough, said (HVAC) system comprising:

a) a ductwork section having duct walls and a generally rectangular cross section, each corner of said rectangular ductwork section having an adjacent pair of channel flanges extending orthogonally from the respective duct walls and orthogonally with respect to each other, wherein end portions of each adjacent pair of orthogonal channel flanges define an open space at each corner of the ductwork section;

b) an angle plate seated at each said corner of said ductwork section in said adjacent pair of orthogonal channel flanges for attaching the ductwork section to a second correspondingly rectangular ductwork section, each said angle plate including two legs formed together in angular relation by an integral corner; and

c) a sealing device for sealing said open space formed between said adjacent pair of orthogonal channel flanges at one of the corners of the ductwork section, said sealing device comprising:

i) a substantially planar first plate member having a surface portion dimensioned and configured for placement in face-to-face relation with corresponding adjacent planar surface portions of said adjacent pair of orthogonal channel flanges, said first plate member provided with at least one attachment device for attachment of said first plate member in position with respect to said pair of orthogonal flange members and corresponding wall portions at the one of the corners of said ductwork section; and

ii) a leg member extending from away from a generally central portion of said first plate member and being generally perpendicular thereto, said leg member comprising second and third orthogonal plate members extending in respective orthogonal planes and having respective orthogonal surface portions said second and third orthogonal plate members configured and dimensioned to engage corresponding respective adjacent orthogonal inner wall surface portions at the respective corner of said ductwork section when said first plate member is positioned on said planar surface portions of the adjacent pair of orthogonal channel flange members, thereby providing an airtight seal for at least a portion of said open space between said adjacent pair of orthogonal channel flange members at the respective corner of said ductwork section.

17. The heating, ventilating and air conditioning system according to claim 16 , wherein each said ductwork section has a square cross-section.