INSULATED REGISTER BOX AND PROCESS FOR FORMING SUCH INSULATED REGISTER BOX

Abstract

A register box for an HVAC installation has a body with a plurality of side panels arranged in a generally rectangular or square configuration and a plurality of flanges extending inwardly from the plurality of side panels, an expandable polymeric material affixed to an inner side of each of the plurality of side panels such that the expandable polymeric material has a portion extending across one end of the body inwardly of the plurality of flanges, and a sheet positioned over the portion of the expandable polymeric material at the one end of the body such that the sheet is interposed between the plurality of flanges and the portion of the expandable polymeric material. The expandable polymeric material and the sheet are cuttable so as to open to the interior of the register box.

Claims

1. A register box for an HVAC installation, the register box comprising: a body having a plurality of side panels arranged in a generally rectangular or square configuration, said body having a plurality of flanges extending inwardly from said plurality of side panel; an expandable polymeric material affixed to an inner side of each of said plurality of side panels, said expandable polymeric material having a portion extending across one end of said body and inwardly of said plurality of flanges; and a sheet positioned over said portion of said expandable polymeric material at the one end of said body.

2. The register box of claim 1, said sheet being interposed between said portion of said expandable polymeric material and said plurality of flanges.

3. The register box of claim 1, said expandable polymeric material defining an opening at an opposite end of said body.

4. The register box of claim 1, said expandable polymeric material having a thickness at each of said plurality of side panels approximately equal to a width of each of said plurality of flanges.

5. The register box of claim 1, said sheet being a foil material.

6. The register box of claim 1, said expandable polymeric material defining an interior of the register box, said expandable polymeric material and said sheet being cuttable so as to selectively open to the interior of the register box.

7. The register box of claim 1, said expandable polymeric material being polyurethane.

8. The register box of claim 1, said body formed from a single sheet of metallic material.

9. A process for insulating a register box, the register box having a plurality of side panels arranged in a generally rectangular configuration and a plurality of flanges extending inwardly of said plurality of side panels at one end of the register box, the process comprising: positioning a sheet of material within said plurality of side panels and against said plurality of flanges; flowing an expandable polymeric material toward said plurality of side panels and toward the sheet of material; placing the register box into or onto a support structure; introducing a liner over the flowed expandable polymeric material within the register box; placing a form onto the liner into the register box so as to shape the expandable polymeric material within the register box; and removing the form and the liner from the register box.

10. The process of claim 9, further comprising: closing a lid over said form and over an end of the register box so as to limit an expansion of the expandable polymeric material.

11. The process of claim 10, further comprising: locking said lid over the end of the register box for a period of time while the expandable polymeric material expands.

12. The process of claim 9, further comprising: positioning said support structure onto an underlying surface prior to the step of placing the register box.

13. The process of claim 9, said support structure having an interior, the step of placing the register box comprising: positioning a polymeric sheet into the interior of said support structure and positioning the plurality of flanges of the register box onto a top of the polymeric sheet.

14. The process of claim 9, the step of introducing said liner comprising: introducing said liner over the flowed expandable polymeric material such that outer edges of said liner reside outwardly of an end of the register box.

15. The process of claim 9, further comprising: lifting the register box from said support structure following the step of removing.

16. The process of claim 9, further comprising: solidifying the flowed expandable polymeric material against the plurality of side panels such that the sheet of material is retained between the solidified polymeric material and the inner surface of the plurality of flanges.

17. The process of claim 16, the plurality of flanges defining in an aperture, the step of solidifying comprising: solidifying the expandable polymeric material against the plurality of side panels such that the solidified expandable polymeric material has a thickness approximately equal to a width of the flange.

18. The process of claim 9, further comprising: forming the register box from a single sheet of metallic material by bending the plurality of flanges inwardly respectively from the plurality of side panels.

19. A register box for an HVAC installation, the register box comprising: a body having a plurality of side panels arranged in a generally rectangular or square configuration, said body having an end panel extending over said plurality of side panels; and an expandable polymeric material affixed to an inner side of each of said plurality of side panels and affixed to an inner side of said end panel, said expandable polymeric material defining an opening within said body that opens at an end of said body opposite said end panel, said body and said expandable polymeric material being cuttable so as to expose said opening through at least one of said plurality of side panels and said end panel.

20. The register box of claim 19, said end panel having flanges that extend over a portion of said plurality of side panels, said flanges being respectively secured to said plurality of side panels.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0040] FIG. 1 is a perspective view of the register box in accordance with the present invention.

[0041] FIG. 2 is a side elevational view of the register box of the present invention.

[0042] FIG. 3 is an end view of the register box of the present invention.

[0043] FIG. 4 is a cross-sectional view of the register box of the present invention.

[0044] FIG. 5 shows an initial step in the forming of the insulated register box of the present invention.

[0045] FIG. 6 shows a further step of the process of forming the insulated register box of the present invention.

[0046] FIG. 7 shows a further step in the forming of the insulated register box of the present invention.

[0047] FIG. 8 is a plan view showing a carousel as used in the process of forming the register box of the present invention.

[0048] FIG. 9 is a side elevational view of the carousel and support structure as used in the formation of the insulated register box of the present invention.

[0049] FIG. 10 is an upper perspective view of an alternative embodiment of the insulated register box of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0050] Referring to FIG. 1, there is shown the insulated register box 10 formed in accordance with the process of the present invention. The register box 10 includes a body 12 having side panels 14, 16, 18 and 20 formed into a generally square or rectangular configuration. A plurality of flanges 14a, 16a, 18a and 20a extend inwardly from and edge of each of the plurality of side panels 14, 16, 18 and 20. A sheet 22 is positioned across the end of the body 12 and against the interior side of each of the flanges 14a, 16a, 18a and 20a. As such, the sheet 22 will extend across the end of the body 12 so as to cover the expandable polymeric material within the body 12. The sheet of material can be a foil material that can be easily cut. The body 12 is formed of a single sheet of metallic material, such as aluminum.

[0051] Since the body 12 is formed of a single sheet of metallic material, the register box 10 will have no seems. As such, this avoids the need for any tack welding operations. This minimizes the amount of time required for the formation of the body 12. The single sheet of metallic material can simply be formed by conventional processes by folding the flange is 14a, 16a, 18a and 20a that right angles with respect to the side panels 14, 16, 18 and 20. This minimizes the amount of labor required for the forming of the body and also minimizes the cost required for forming the body. The present invention involves a minimal number of operations for the forming of the body 12.

[0052] FIG. 2 shows a side view of the register box 10. As can be seen in FIG. 2, the side panel 14 is particularly illustrated. There is a lip 44 that extends outwardly of the end 46 of the body 12. The lip 44, as will be described hereinafter, extends outwardly of a flange 48. Flange 48 extends inwardly from the side panels 14, 16, 18 and 20 such that the inner edges define an aperture 50 opening to the interior of the body 12.

[0053] FIG. 3 is an end view of the register box 10 of the present invention. Sheet 22 is illustrated as located centrally within the flanges 14, 16, 18 and 20. Sheet 22 will overlie the expanded polymeric material within the interior of body 12. The flanges 14, 16, 18 and 20 define a generally central area into which the sheet of foil material 22 resides. In normal use, when it is desired to adapt the insulated register box 10 to a particular size of ductwork or other air moving equipment, the sheet 22, along with the expanded polymeric material, can be easily cut with a knife to the desired dimensions of the duct or tubular to which the insulated register box 10 is to be connected. The surface-to-surface contact between the expanded polymeric material on the interior of the register box 10 will tightly conform to the exterior of any duct or tubular that would extend through the opening formed in the sheet 22.

[0054] FIG. 3 shows the nature of the flanges 14a, 16a, 18a and 20a. These flanges 14a, 16a, 18a and 20a extend around the interior of the body 12. Each of the flanges has a similar width. In accordance with the present invention, and as will be described in association with FIG. 4, the expanded polymeric material will reside against the side panels 14, 16, 18 and 20 and have a thickness approximately equal to the width of the flanges 14a, 16a, 18a and 20a.

[0055] FIG. 4 is a cross-sectional view of the register box 10 of the present invention. As can be seen in FIG. 4, the expanded polymeric material 60 is illustrated as positioned against the side panels 14 and 18. A similar configuration will occur with respect to side panels 16 and 20. The expanded polymeric material is illustrated as having a thickness approximately equal to the width dimension of the flanges 14a and 18a. The sheet 22 is interposed between the expanded polymeric material 60 and each of the flanges 14a and 18a. As such, the sheet of material 22 will be properly retained in a position adjacent to an opening 23 at the end of the body 12. The expanded polymeric material 60 will define an interior 61. An aperture 64 also opens at the opposite end of the body 12 to the interior 61.

[0056] As was described herein previously, when a person desires to fit the insulated register box 10 to existing ductwork or air moving facilities, is only necessary to form a hole through the sheet 22 and through the expanded polymeric material so as to access the interior 61. The insulated register box 10 can then be fit to existing ductwork. The expanded polymeric material 60 serves as insulation. This insulation is compliant with national building codes, is fire resistant, and also avoids the use of fibrous insulation material. As such, this type of material, since it avoids the fibrous material in the assembly procedures, it will improve the health and safety of workers that assemble the register box 10. The insulation created by the expanded polymeric material 60 does not require any alterations in the structure of the body 12. The insulation material causes the register box 10 to be very energy efficient.

[0057] FIG. 5 illustrates an early step in the process of forming the register box of the type shown in FIGS. 1-4. In FIG. 5, it can be seen that there is a supply 102 of the expandable polymeric material. The expandable polymeric material, in the preferred embodiment of the present invention, is polyurethane. A conduit 104 extends from the supply 102 to a foam gun 106. As such, the foam gun 106 will inject foamed expandable polymeric material 108 toward the interior of the register box 110. The register box 110 includes a plurality of side panels 112 arranged in a generally rectangular configuration of the type described hereinbefore. It can be seen that the foamed expandable polymeric material is flowed generally toward the wall 116 and also around the plurality of side panels 112. The register box 110 is maintained and moved at an angle so as to allow the person operating the foam gun 106 to direct the foam expandable polymeric material 108 generally around the interior of each of the plurality of side panels 112.

[0058] A support structure 118 is illustrated as located below the register box 110. In the preferred embodiment of the present invention, the support structure 118 is a frame that has sides 120 and an interior 122. After the foamed expandable polymeric material is directed generally around the side panels 112 and the wall 116, the register box 110 will be introduced into the interior 122 of support structure 118.

[0059] In FIG. 6, the support structure 118 is placed upon an underlying surface 126. As will be described hereinafter, in the preferred embodiment of the present invention, the support structure 126 can be a carousel. The flange 116 can be placed directly upon a polymeric sheet 117 located on the top of the support structure 118. The polymeric material of the sheet 117 will prevent any adhesion that may occur between the expanded polymeric material 108 and the support structure 118. The sheet of foil material 119 has been previously placed upon the flanges 116. The sheet of foil material 119 can be placed upon the inner surface of the flanges 116 prior to the introduction onto the support structure 118 or after the introduction into the support structure 118. The foamed expandable polymeric material 108 is illustrated as residing against the plurality of side panels 112 and over the sheet of foil material 119 and over the flanges 116.

[0060] In FIG. 6, it can be seen that the register box 110 has flanges 128 that extend inwardly from the plurality of side panels 112. Flanges 128 will extend inwardly from an edge of the side panels 112 opposite the sheet of foil material 119. Flanges 128 can define an aperture of the register box 110.

[0061] With reference to FIG. 6, after the foamed expandable polymeric material 108 has been introduced into the interior of the register box 110, a liner 130 is placed over the expandable polymeric material. The liner 130 will include edges 132 which extend outwardly of the register box 110. As such, these edges 132 can provide a grasping surface. A form 134 is then placed upon the liner 130 and into the interior of the register box 110. The form 134 is a metal plug. The form 134 is intended to shape the insulation of the register box 110. As such, it will have a shape that corresponds to the intended shape of the insulation on the interior of the register box 110. As described herein, the liner 130 can be a plastic sheet or it can be a surface that is formed on the form 134. The purpose of the liner 130 is to allow the separation of the form 134 from the solidified expanded polymeric material 108.

[0062] An adjustable hold-down 136 is maintained by a support 138. Adjustable hold-down 136 serves to secure the register box 110 on the support structure 118 and also to maintain the register box 110 and the support structure 118 upon the underlying surface 126. A lid 140 is illustrated as extending upwardly from a member 142. The lid 140 is connected to the member 142 by a hinge 144. Member 142 extends upwardly from the underlying surface 126 in proximity to one of the panels of the register box 110. A latch 146 is located adjacent to an opposite side of the register box 110. Latch 146, as will be described hereinafter, serves to receive the end 148 of the lid 140 so as to lock the lid 148 in positioned over the form 134 and over the top of the register box 110.

[0063] FIG. 7 shows a further step in the process of the present invention. In FIG. 7, it can be seen that the lid 140 is pivoted downwardly about the hinge 144 so as to be juxtaposed against the top of the form 134. The end 148 is locked in position by the latch 146. Importantly, in this configuration, the lid 140 provides resistance against the expansion of the expandable polymeric material 108 within the register box 110. As such, the expandable polymeric material 108 can properly solidify in a desired configuration within the interior of the register box 110. This is important since polyurethane has generally irregular expansion characteristics. The lid 140 will confine this expansion of the expandable polymeric material 108 to the shape that is desired so as to form the installation of the register box 110.

[0064] After the expandable polymeric material 108 has solidified, the lid 140 can be pivoted upwardly and unlatched from latch 146. With reference to FIG. 6, the outwardly extending edges 132 can be grasped and lifted upwardly so as to remove the form 134 from the interior of the register box 110. The solidified polymeric material 108 will have the desired shape and configuration shown in FIGS. 1-4. Ultimately, the adjustable hold-down 136 can be moved away from the register box 110 so as to allow the register box 110 to be lifted upwardly and removed from the support structure 118. As such, a properly formed register box is achieved. As was described hereinafter, the solidified expandable polymeric material 108 will have a thickness at the side panels 112 generally equal to the width of the flange 128. Similarly, the expandable polymeric material 108 will have a suitable thickness extending upwardly from the wall 116.

[0065] The expanded polymeric material 108 can include portions that emerge through small cracks or gaps in the seams associated with the register box 110, as described hereinbefore. In particular, the solidified expanded polymeric material 108 can flow outwardly through the small seams that exists in the wall 114 of the register box 110.

[0066] The process of the present invention greatly improves the efficiency of the production of insulated register boxes. In the past, a great deal of manual activity was required so as to install the fibrous insulating material against the various side panels and wall of the register box. In the present invention, since fibrous insulating material is not required, the present invention can rapidly create insulated register boxes.

[0067] FIG. 8 shows a carousel 200 that is provided with a plurality of the support structures 202, 204, 208, 210, 214, 216, 218, 220, and 222. Support structures 202, 204 and 208 are illustrated in a position prior to receiving the register box therein. As such, the support structure 204 will have an interior 207 which serves to receive the register box.

[0068] The support structure 210 has the register box 212 therein. This register box 212 is formed in accordance with the teachings of the present invention hereinbefore. As one register box 212 is initially formed, it can be rotated on the carousel 200 so as to move to another position. As such, another insulated register box can be placed onto the support structure 208 and the process carried out thereafter. That carousel 200 will continue to rotate until the insulated register box 224 reaches and end of the rotation of the carousel 200. As such, a worker can lift the register box 224 from the support structure 222 for the purposes of storing the complete register box. Thereafter, another register box can be introduced onto the support structure 222 and the process continues onward. Unlike previous insulated register boxes, the process of the present invention greatly facilitates the ability to stack. Since the expanded polymeric material will solidify in approximately two minutes, the process associated with carousel 200 is relatively rapid.

[0069] FIG. 9 is a side view showing the arrangement of the carousel 200 and the various register boxes and support structures 210 thereon. In particular, in FIG. 9, it can be seen that the carousel 200 is rotatably mounted on a support 230. The support 230 is maintained in an upright position by a base 232. Each of the support structures 210 (including the register boxes thereon) are arranged on the top surface 240 of the carousel 200.

[0070] FIG. 10 shows an alternative embodiment of the register box 200 in accordance with the present invention. The register box 200 includes a body 202 having a plurality of side panels 204 and 206 arranged in a generally rectangular or square configuration. An end panel 208 extends over the plurality of side panels 204 and 206 so as to generally enclose one end of the body 202. An expandable polymeric material, as described in the previous embodiments of the present invention, is affixed to an inner side of each of the plurality of side panels 204 and 206 (including the side panels not illustrated in FIG. 10). The expandable polymeric material is also affixed to an inner side of the end panel 208 so as to extend entirely thereacross. As with the previous embodiments of the present invention, the expandable polymeric material defines an opening within the body 202 that opens at an end 210 opposite the end panel 208. The body 202 and the expandable polymeric material are cuttable so as to expose the opening through at least one of the plurality of side panels 204 and 206 and the end panel 208.

[0071] In FIG. 10, the broken lines 212 and 214 illustrate the manner in which a hole can be formed in the respective side panels 204 and 206 and through the expandable polymeric material on the inside of each of the side panels 204 and 206. Alternatively, if desired, a similar type of hole can be formed through the end panel 208. As such, the opening on the interior of the expandable polymeric material is exposed through the side panels 204 and 206.

[0072] It can be seen that the end panel 208 has flanges 216 and 218 (including flanges that are not shown in FIG. 10 on the other sides of the end panel 208). These flanges 216 in 218 will extend over the respective side panels 204 and 206. As such, during assembly, the end panel 208 is simply placed onto an over the end of the body 212. Tack welding can be used so as to affix the flanges 216 and 218 to the respective side panels 204 and 206 of the body 202.

[0073] The embodiment of the register box 200, as shown in FIG. 10, is particularly configured for adaptation to the existing ductwork of the HVAC system. Often, the arrangement of the ductwork can vary considerably from location to location. As such, if it is desired to access the opening of the expandable polymeric material on the interior of the register box 200, a worker can simply cut a hole (such as holes 212 and 214) through one of the side panels 204 and 206 and through the expandable polymeric material on the inside of each of the side panels. As such, the opening on the interior of the register box 200 is accessible through one of the side panels. Existing ductwork can then be placed through the hole that is been formed through the side panel. The configuration of the expandable polymeric material on the inside of the body 202 will form a seal with the exterior of any ductwork that is inserted through either of the holes 212 and 214. As such, the register box 200 is particularly adaptable for on-site installation.

[0074] 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 within the scope of the present claims without departing from the true spirit of the invention. The present invention should only be limited by the following claims and their legal equivalents.