METHOD FOR RETROFITTING A REGISTER BOX WITH AN EXPANDABLE POLYMERIC FOAM MATERIAL

Abstract

A method of insulating a register box in which the register box has a body and a duct. The method includes accessing the register box such that the interior of the register box can be reached, removing existing insulation from the interior of the body of the register box, injecting an expandable polymeric material into the interior of the body of the register box, and allowing the expandable polymeric material to cure for a period of time. The opening of the duct of the register box is blocked during the step of curing. The step of injecting includes inserting a foam gun into an interior of the body of the register box and directing the expandable polymeric material from the foam gun toward a wall of the body of the register box.

Claims

1. A method of insulating a register box, the register box having a body and a duct which opens to an interior of the body, the method comprising: accessing the register box such that the interior of the register box can be reached; removing existing insulation from the interior of the body of the register box; injecting an expandable polymeric material into the interior of the body of the register box; and allowing the expandable polymeric material to cure for a period of time within the interior of the body of the register box.

2. The method of claim 1, further comprising: blocking an opening of the duct during the step of curing.

3. The method of claim 2, the step of blocking comprising: inserting a cylindrical or rectilinear member into the interior of the body of the register box so as to bear against the opening of the duct.

4. The method of claim 3, the step of blocking further comprising: placing a sheet of a polymeric film over a portion of the exterior of the cylindrical or rectilinear member during the step of inserting the cylindrical or rectilinear member such that the sheet of polymeric film is interposed between the opening of the duct and an end of the cylindrical or rectilinear member, the sheet of polymeric film being interposed between the cylindrical or rectilinear member and the expandable polymeric material in the body of the register box.

5. The method of claim 1, the register box being affixed to sheetrock, the body of the register box having an opening extending through a thickness of the sheetrock, the step of injecting comprising: inserting a foam gun into the opening of the body of the register box; and directing the expandable polymeric material from the foam gun toward a wall of the body of the register box.

6. The method of claim 5, further comprising: rotating the foam gun so as to direct the expandable polymeric material from the foam gun toward all side walls of the body of the register box.

7. The method of claim 5, further comprising: applying a nozzle to the foam gun, the nozzle being affixed to an outlet of the foam gun.

8. The method of claim 7, the nozzle being a replaceable straw.

9. The method of claim 5, further comprising: positioning a panel over the opening of the body of the register box, the panel having a port therethrough; and extending a portion of the foam gun through the port of the panel so as to enter the interior of the body of the register box.

10. The method of claim 9, further comprising: removably affixing the panel to the sheetrock.

11. The method of claim 5, the step of removing existing insulation comprising: pulling the existing insulation from the interior of the register box by hand through the opening of the body of the register box.

12. The method of claim 9, the panel having an elastomeric gasket positioned on a surface thereof, the step of positioning the panel comprising: placing the panel such that the elastomeric gasket bears against edges around the opening of the body of the register box.

13. The method of claim 12, the port extending through the elastomeric gasket.

14. The method of claim 1, the register box being affixed to a floor, the body of the register box having an opening extending through a thickness of the floor, the step of injecting comprising: inserting a foam gun into the opening of the body of the register box; and directing the expandable polymeric material from the foam gun toward a wall of the body of the register box.

15. The method of claim 14, further comprising: positioning a panel over the opening of the body of the register box, the panel having a port therethrough; and extending a portion of the foam gun through the port of the panel so as to enter the interior of the body of the register box.

16. The method of claim 15, further comprising: removably affixing the panel to the floor.

17. The method of claim 5, the foam gun having a nozzle formed from a replaceable straw, the method further comprising: removing the nozzle from the foam gun following the step of injecting the expandable polymeric material.

18. The method of claim 9, further comprising: removing the panel following the step of injecting the expandable polymeric material.

19. The method of claim 1, the expandable polymeric material being polyurethane.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0042] FIG. 1 is a side cross-sectional view showing the injection of expandable polymeric material into the interior of an existing register box.

[0043] FIG. 2 shows the placement of a blocking member into the interior of the existing register box after the step of injecting.

[0044] FIG. 3 is across-sectional view showing the completed installation of the expandable polymeric foam material into the existing register box.

DETAILED DESCRIPTION OF THE INVENTION

[0045] Referring to FIG. 1, there is shown a step in the process of retrofitting an existing register box with an expandable polymeric foam material. In particular, the existing register box has a body 12 and a duct 14. The duct 14 has an opening 16 that opens to the interior 18 of the body 12. The body 12 is of a generally of a rectangular configuration can include side walls 20 and 22. The side wall 22 extends so as to have flange 24 extending upwardly into the interior 18 of the body 12. Side 20 includes flange 26 extending upwardly into the interior of the body 12. The register box 10 is installed into sheetrock 28 in a rather permanent manner.

[0046] In the present invention, the register box 10 is an existing register box which is filled with a fibrous insulation. In view of the problems associated with fibrous insulation, along with the deterioration of such fibrous insulation over time, it is important to be able to replace such fibrous insulation with an expandable polymeric material so as to achieve the advantages of such expandable polymeric material recited hereinabove. As such, the opening 30 to the body 12 of register box 10 is accessed. Typically this access can be achieved by removing the grate or screen extending over the opening 30. The interior 18 of the register box 10 will then be accessible by hand. The fibrous insulation can be removed from the interior 18 of the register box 10 by hand by pulling such fibrous material through the opening 30 and disposing of the fibrous material. As such, a register box 10 void of insulation is created. The next step in the method of the present invention is to introduce the expandable polymeric material into the interior 18 of the register box 10. As can be seen in FIG. 1, a panel 32 is placed over the opening 30 of the body 12 of register box 10. Panel 32 can be of a sheet metal material, or of other rigid construction. An elastomeric or rubber gasket 34 is positioned over a face of the panel 32 so as to be interposed between the panel 32 and the edges of the opening 30. As such, a generally liquid-tight configuration is achieved by virtue of this gasket 34 in combination with the panel 32. A port 36 extends through the panel 32 and through the gasket 34. Port 36 will allow access to the interior 18 of the register box 10.

[0047] FIG. 1 shows that there is a foam gun 38 having a nozzle 40. The nozzle 40 has a generally angular configuration. Nozzle 40 serves to direct a stream of polymeric foam material 42 toward one of the side walls 20 and 22 of the body 12 of register box 10. Nozzle 40 is connected to an outlet of the foam gun 38. Foam gun 38 includes a trigger 44 that allows an operator to draw the expandable polymeric foam material through conduit 46 attached to a supply of such polymeric foam material. The polymeric foam material is released from the nozzle 40. It is generally important that the polymeric foam material be directed so as to reside between the flange 24 and the side wall 22 (or between the side wall 20 and the flange 26). The foam gun 38 is rotatable (as shown by arrow 50) so that the expandable polymeric material 42 is directed to all of the side walls of the body 12 of the register box 10.

[0048] In the present invention, the nozzle 40 is in the nature of a replaceable straw. It is important to note that every time the foam gun 38 is used and expandable polymeric material 42 is introduced into the register box 10, a certain amount of the expandable polymeric material would cling to the inner walls of the replaceable straw. Over time, this can impede the ability to effectively deliver the expandable polymeric material. As such, the nozzle 40 should be replaced after a certain period of time or between applications of the expandable polymeric material.

[0049] It can be seen that the register box 10 is placed in sheetrock 28. Sheetrock 28 acts as the ceiling of a building or home. In other embodiments, the sheetrock 24 can be in the nature of side walls of the building or home. Still, in other applications, the sheetrock can be a floor of a building. In those circumstances where the sheetrock 28 is not actual sheetrock, but a floor of a building, the configuration of FIG. 1 is reversed such that the register box 10 is on the bottom and the foam gun 38 is on top.

[0050] In the embodiment shown in FIG. 1, it is actually the foam gun 38 that is rotated by a user. The user can be standing on a ladder and simply rotate the foam gun so as to introduce the expandable polymeric material into the interior 18 of the register box 10. In other circumstances, mechanical means can be utilized in conjunction with the foam gun 38 such that the nozzle 40 is rotated so as to evenly introduce the expandable polymeric material 42 throughout the interior of the register box 10. Such rotation can occur upon the pulling of the trigger 44. FIG. 1 further shows that there is a support 52 affixed to a side of the panel 32 opposite the elastomeric gasket 34. Support 52 includes an opening 54 for further support of the foam gun 38 and the nozzle 40.

[0051] FIG. 2 shows the configuration of the register box 10 of the present invention after the expandable polymeric material 42 has been introduced. In FIG. 2 it can be seen that the expandable polymeric material 42 resides against the side walls 20 and 22 of the body 12 of register box 10. The duct 14 has its opening 16 positioned away from the opening 30 of the body 12. In this configuration, the expandable polymeric material 42 will not enter the interior of the duct 14. If any expandable polymeric material would enter the interior of the duct 14 through the opening 16, it could block the flow of air passing through the duct 14. As such, as the expandable polymeric material 42 cures, it is important to avoid the expansion of such expandable polymeric material into the opening 16 and into the interior of the duct 14. It is also important to form a cavity within the body 12 so that the expandable polymeric material is configured into a desired shape for air flow.

[0052] In particular, FIG. 2 shows that there is a cylindrical or rectilinear member 60 that is adapted for installation through the opening 30 of the body 12 of register box 10 and against the opening 16 of the duct 14. The cylindrical or rectilinear member 60 has an end 62 having a diameter or width greater than the diameter of the opening 16 of duct 14. As such, when the member 60 is introduced into the opening 30 and bears against the opening 16 of the duct 14, it will block the flow of the expandable polymeric material into the opening 16 of duct 14. The sides of the member 60 will also create the void within the interior 18 of register box 10 that allows air to flow therethrough.

[0053] At this stage, the foam gun 38 and nozzle 40 have been removed from the interior 18 of the body 12. Additionally, the panel 32 and elastomeric gasket 34 have been removed. As such, the opening 30 of the register box 10 is exposed. At this stage, the expandable polymeric material 42 will cure so as to expand and solidify. This covers all the exposed edges, joints and surfaces of the register box 10.

[0054] In order to create the void within the interior of the register box 10, a sheet of polymeric film 70 is provided. The sheet a polymeric film 70 will be placed so as to extend over the end 62 and sides of the cylindrical or rectilinear member 60. As such, when the member 60 is inserted into the opening 30 so as to bear against the opening 16 of duct 14, the sheet a polymeric film 70 will be interposed between the end 62 and the edges of the opening 16. Similarly, the sheet a polymeric film 70 will reside over the sides of member 60 so as to be interposed between the expandable polymeric material and the member 60. Upon curing, the member 60 can be easily removed because of this sheet of polymeric film.

[0055] FIG. 3 shows the configuration of the present invention after the expandable polymeric material 42 has cured. As can be seen, there is a void 80 created in the interior of the body 12 of register box 10. None of the expandable polymeric material 42 has entered the interior 82 of duct 14. Because of the use of the member 60 and the sheet of polymeric film 70, the opening 16 of duct 14 is free of the expandable polymeric material. As such, air flow through the interior 82 of the duct 14 is unimpeded.

[0056] FIG. 3 shows that the register box 10 continues to be embedded in the sheetrock 28. As such, the present invention provides a technique whereby the expandable polymeric foam material 42 can be retrofitted into an existing register box without removing the register box 10 from the sheetrock 28 or causing the damage or destruction of the sheetrock 28. This installation can be carried out in a simple and effective manner. As such, the present invention provides the benefits of the expandable polymeric material without the need for the replacement of the entire register box.

[0057] The foregoing disclosure and description of the invention is illustrative and explanatory thereof. Various changes in the details of the illustrated construction can be made is the scope of the present invention without departing from the true spirit of the invention.