INSULATED REGISTER BOX WITH BOOT RAIL ADAPTOR

Abstract

An insulated register box apparatus with a boot rail adapter has a register box, an insulating material affixed within the register box, a rail affixed to a side panel of the register box, and a rail guide having a slot that receives a section of the rail therein. The rail guide is adapted to be affixed to a supporting surface. The rail is affixed to at least one of the side panels of the register box. The rail is slidable relative to the rail guide. The register box has a plurality of side panels and a duct that opens to an interior of the plurality of side panels. The insulating material extends inwardly of the plurality of side panels.

Claims

1. An apparatus comprising: a plurality of side panels and a duct opening to an interior of said plurality of side panels; an insulating material affixed to said plurality of side panels and extending inwardly of said plurality of side panels; a rail guide defining a slot that extends longitudinally along said rail guide, said rail guide adapted to be affixed to a supporting surface; and a rail having a section received in said slot of said rail guide, said railed affixed to at least one of said plurality of side panels of said register box.

2. The apparatus of claim 1, said rail guide being slidable relative to said rail.

3. The apparatus of claim 2, said rail being affixed to an exterior surface of said side panel.

4. The apparatus of claim 3, said rail being affixed to said exterior surface of said side panel without the use of fasteners.

5. The apparatus of claim 1, said rail comprising a first rail affixed to a first side panel of said plurality of side panels and a second rail affixed to a second side panel of said plurality of side panels, said first side panel being on an opposite side of said register box from said second side panel.

6. The apparatus of claim 5, said rail guide comprising a first rail guide and a second rail guide, said first rail guide receiving said first rail, said second rail guide receiving said second rail.

7. The apparatus of claim 1, said rail having a first surface affixed to said side panel and a second surface extending transversely outwardly of said first surface.

8. The apparatus of claim 7, said rail guide comprising a first surface adapted to be affixed to the underlying surface, a second surface extending inwardly from a side of said first surface, and a third surface extending in spaced relationship to said second surface on a side of said second surface opposite said first surface, said third surface having an inwardly turned edge.

9. The apparatus of claim 8, said slot of said rail guide defined by said second and third surfaces, said section of said rail being received between said second and third surfaces.

10. The apparatus of claim 9, said section of said rail having at least one projection extending toward said third surface of said rail guide, said projection cooperative with said inwardly turned edge so as to lock said rail guide to said rail.

11. The apparatus of claim 1, the support surface being a joist, said rail guide being affixed to said joist, said register box having a portion extending away from said joist.

12. The apparatus of claim 11, said joist comprising a first joist and a second joist extending in parallel relation to each other, said rail guide comprising a first rail guide and a second rail guide, said first rail guide being affixed to said first joist and to said second joist, said second rail guide being affixed to said first joist and to said second joist in parallel relation to said first rail, said rail comprising a first rail and a second rail, said first rail received by said first rail guide, said second rail received by said second rail guide.

13. The apparatus of claim 1, said insulating material being an expanded polymeric material.

14. The apparatus of claim 1, said rail affixed to the side panel by a clinch lock.

15. A method for positioning a register box upon a supporting surface, the method comprising: affixing a rail to an exterior surface of the register box, said rail having a section extending outwardly of said exterior surface of said register box; inserting the section of the rail into a slot of a rail guide such that the rail is secured to the rail guide; and fastening the rail guide to the supporting surface such that the register box extends away from the supporting surface.

16. The method of claim 15, further comprising: sliding the section of the rail longitudinally along the slot of the rail guide so as to position the register box in a desired position with respect to the supporting surface.

17. The method of claim 15, the step of affixing comprising: attaching the rail to the exterior surface of the register box without penetrating the register box.

18. The method of claim 15, the supporting surface being a first joist and a second joist, the step of fastening comprising affixing the rail guide to the first joist such that the register box is positioned between the first and second joists.

19. The method of claim 18, the rail guide comprising a first rail guide and a second rail guide, the step of fastening comprising: affixing the first rail guide to the first and second joists such that the first rail guide extends between the first and second joists; and affixing the second rail guide to the first and second joists such that the second rail guide extends between the first and second joists in parallel relation to the first rail guide.

20. The method of claim 15, the step of inserting comprising: snap-fitting the section of the rail into the slot of the rail guide such that the rail guide is locked upon the rail.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0052] FIG. 1 is a perspective box showing the register box of the present invention.

[0053] FIG. 2 is a side elevational view of the register box of the present invention.

[0054] FIG. 3 is a is a bottom view of the register box of the present invention.

[0055] FIG. 4 is a cross-sectional view of the register box of the present invention.

[0056] FIG. 5 is a perspective view showing the register box as secured to the boot rail adapter.

[0057] FIG. 6 is a bottom perspective view of the previous embodiment of the present invention showing the installation of the register box with the boot rail adapter to a supporting structure.

[0058] FIG. 7 is a perspective view showing the register box in an initial step of installation in the previous embodiment of the present invention.

[0059] FIG. 8 is an exploded view showing the boot rail assembly of the register box of the previous embodiment of the present invention.

[0060] FIG. 9 is a detailed perspective view of the circled area of FIG. 8 showing the securing of the guide rail to the rail in this previous embodiment of the present invention.

[0061] FIG. 10 is an end view of the guide rail of the boot rail assembly of the register box of the previous embodiment of the present invention.

[0062] FIG. 11 is a perspective and exploded view showing the relationship of the rail and the rail guide of the present embodiment of the present invention.

[0063] FIG. 12 is a perspective view showing the securing of the register box to the pair of guide rails in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0064] Referring to FIG. 1, there is shown the insulated register box 10 of the present invention. The register box 10 includes a body 12 having side panels 14, 16, 18 and 20 formed into a generally rectangular configuration. A wall 22 extends across this generally rectangular configuration. A duct 24 is illustrated as affixed to the wall 22 so as to open to the interior of the body 12. The duct 24 includes an open end 26 so as to allow duct 24 to be connected to the HVAC system of a building.

[0065] Conventionally, the register box 10 will be formed and pieced together through the use of tack welding. Tack welding is a very efficient manner of forming the register box. Unfortunately, tack welding can often leave gaps and seams in certain areas through which air can penetrate. In particular, the duct 24 can be tack welded to the body 22. Similarly, portions of the body 12 can be tack welded together. As illustrated in FIG. 1, there is a seam 28 that occurs between the duct 24 and the wall 22 of body 12 and also a seam 30 that is located on the side panels 14 and 16.

[0066] As will be described hereinafter, an expandable polymeric material, such as polyurethane, is applied for the purposes of insulating the interior of the body 12. In FIG. 1, it can be seen that a portion 32 of the expanded polymeric material actually emerges through the seam 28 so as to reside outwardly on the exterior of the duct 24. Another portion 34 of the expanded polymeric material is illustrated as residing on an exterior surface of the wall 22. Similarly, a portion of the expanded polymeric material 36 extends outwardly through the seam 30 and resides on the exterior of the body 12. This is an important feature of the present invention.

[0067] Fundamentally, expanded polyurethane material will expand in an irregular manner. As such, as the polyurethane material expands, it will tend to flow through any pores, gaps, seams and openings. As such, the various portions 32, 34 and 36 of the expanded polymeric material will actually penetrate through the seams. This effectively closes the seams and enhances the air-tightness of the register box 10. Additionally, since this expanded polymeric material can actually be seen on the exterior of the register box, it can be easily viewed by inspectors to see if a register box is insulated or not. To enhance this quality, the expanded polymeric material should be of a different color than the color of the register box. As such, although this seepage of the expanded polymeric material creates an unpleasing and unaesthetic appearance, it facilitates installation and facilitates inspection. Since the register box 10 is typically maintained in an unobservable location, the unpleasing appearance of this seepage is of little or no aesthetic importance.

[0068] 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. Side panel 14 includes another seam 38. Portions 40 and 42 of the expanded polymeric material are illustrated as emerging out of the seam 38. Additionally, the duct 24 is illustrated as affixed to and extending outwardly of the wall 22. The portions 32 of the expanded polymeric material are illustrated as extending between through the seam 28 between the duct 24 and the wall 22 and residing on the exterior of the duct 24. In FIG. 2, it can be seen that 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.

[0069] FIG. 3 is an end view of the register box 10 of the present invention. In FIG. 3, it can be seen that the duct 24 is affixed to the wall 22. Wall 22 includes a surface 52 that extends from the opening of the duct 24 to the side panels 14, 16, 18 and 20 of the body 12. In FIG. 3, it can be seen that the expanded polymeric material 60 resides over the surface 52 and extends to the side panels 14, 16, 18 and 20. As such, the expanded polymeric material 90 effectively insulates the wall 22 in the area adjacent to the opening of the duct 24.

[0070] FIG. 3 further shows the nature of the flanges 48. Flange 48 is illustrated as extending around the interior of the body 12. Flange 48 has a particular width. In accordance with the present invention, and as will be described in association with FIG. 4, the expanded polymeric material 60 will reside against the side panels 14, 16, 18 and 20 and have a thickness approximately equal to the width of the flanges 48. The lip 50 is illustrated as extending in transverse relationship from the flange 48.

[0071] 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, such as shown in FIG. 4, will occur with respect to the side panels 16 and 20. The expanded polymeric material 60 is illustrated as having a thickness approximately equal to the width dimension of the flange 48. The flange 48, along with the lip 50 defines an aperture 64 that opens to the interior of the body 12. The expanded polymeric material 60 also has a portion 60 that resides against the inner surface of the wall 22. This portion 60 extends from the side panels 14 and 18 so as to generally be aligned with the opening of the duct 24.

[0072] In this configuration, the expanded polymeric material 60 can serve as an insulation. This installation 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 requirements, improves 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 or of the duct 24. The insulation material causes the register box 10 to be very energy efficient. Also, since the expanded polymeric material 60 enters and emerges through the various openings, gaps, seams, and holes in the register box 10, it minimizes air loss and improves inspectability.

[0073] In FIG. 4, it can be seen that there is no expanded polymeric material located on the inner wall 68 of the duct 24. If any expanded polymeric material would enter the duct 24 or reside on the inner wall 68 of the duct 24, then it could hamper air circulation. As such, it was felt that it was important to block any movement of the expanded polymeric material from entering the area on the interior of the duct 24. Since the expanded polymeric material 60 extends to the aperture 64 that is defined by the lips 50 and the flanges 48, it does not interfere with airflow into the interior of the register box. As such, the present invention remains substantially aerodynamic while, at the same time, improving the insulating qualities required of the register box 10.

[0074] FIG. 5 shows the boot rail assembly 70 as secured to the register box 10. In accordance with the teachings of the parent application of U.S. patent application Ser. No. 15/703,436. As described hereinbefore, the register box 10 has a body 12 with side panels 14, 16, 18 and 20. The body 12 is formed into a generally rectangular configuration. The wall 22 extends across this generally rectangular configuration. The duct 24 includes an open end 26 so as to allow the duct 24 to be connected to the HVAC system of the building.

[0075] The boot rail assembly 70 includes a guide rail 72 and a rail 74. The rail 74 is illustrated as having a section 76 that extends in transverse relationship to a planar surface 78. The section 76 will be received by the guide rail 72. The guide rail 72 will be affixed to the side panel 14 of the register box 10 without fasteners. In particular, the guide rail 72 is affixed to the side panel 17 through the use of a clinch lock. A clinch lock simply forms the surface of the guide rail 72 with a surface of side panel 14 so as to effectively lock the guide rail 72 to the side panel 14. In this manner, there are no penetrations of the material used for the side panel 14 and no potential damage to the insulation.

[0076] There is another rail 80 positioned in spaced relation to the first rail 74. The register box 10 will also include another guide rail (not shown) that has a similar structure to that of guide rail 72. The section 82 of the second guide rail 80 will be received within a slot formed in the guide rail that is affixed to wall 20 of the body 12 of register box 10.

[0077] As will be described hereinafter, the planar surface 78 of the rail 74 and the planar surface 84 of the rail 80 will be affixed to a supporting surface. The supporting surface can be in the nature of respective joists. In this configuration, the register box 10 will be positioned between the rail 74 and 80. As such, the register box 10 will be positioned between the joists and extend upwardly therefrom. FIG. 5 has an arrow 86 that shows the slidability of the register box 10 relative to the rails 74 and 80 (and the respective joists to which these rails are connected). As such, the present invention is able to provide proper adjustability of the location of the register box 10.

[0078] FIG. 6 shows the register box 10 as secured between joists 88 and 90. As can be seen, the first rail 74 has one end fastened to the joist 88 and an opposite end fastened to the joist 90. The second rail 80 has one end affixed to the first joist 88 and an opposite end affixed to the second joist 90. The rail 74 and 80 extend in parallel relationship to each other. The register box 10 is illustrated as having an aperture 92 opening at the bottom thereof. The aperture 92 will be located between the rails 74 and 80. This configuration showing that the register box 10 (in relation to the illustration of FIG. 5) can slide in a direction toward the joist 88 and in an opposite direction to the joist 90 so as to provide for proper adjustability between the joists 88 and 90. Alternative mounting could be carried out so as to allow slidability along the joists.

[0079] FIG. 7 shows an initial step of the method of the present invention. As can be seen in FIG. 7, the guide rail 72 is fastened to side panel 14 of register box 10. Another guide rail (similar to guide rail 72) will be affixed to the side panel 20 of register box 10. The guide rail 72 is located generally adjacent to the bottom of the side panel 10.

[0080] FIG. 8 shows the relationship between the rail 74 and the guide rail 72. As can be seen, the register box 10 is brought into proximity to the upwardly turned section 76 of rail 74. In particular, a worker will cause the guide rail 72 to overlie this upturn section 76 as part of the installation process.

[0081] FIG. 9 shows a further step in the installation of the register box 10 upon the rail 74. In particular, there is a slot 94 formed in the guide rail 72. Importantly, it can be seen that slot 94 will receive the upturned section 76 of the rail 74. The upturned section 76 will include projections 96 that extend inwardly. As such, when the guide rail 72 receives the upturned section 76 in slot 94, the projections 96 will lock the guide rail 72 to the rail 74. However, the guide rail 72 is free to slide along the rail 74 without interference by the projections 96. The projections 96 serve to resist any lifting forces applied to the register box 10 while allowing sliding forces to move the register box 10 to any location along the rail 74.

[0082] FIG. 10 shows the structure of the guide rail 72. The guide rail 72 has a first surface 100 which bears against the side panel which will be affixed to the exterior surface of the side panel of the register box. In particular, it is affixed without the use of fasteners through the use of a clinch lock. A second surface 102 extends upwardly from the bottom of the first surface 100. A third surface 104 extends downwardly from the upper portion of the second surface 102. There is an upturned edge 106 formed at the bottom of the third surface 104 and which extends inwardly thereof As such, the second surface 102 and the third surface 104 defines the slot 94.

[0083] In application, the upwardly extending section 76 of the rail 74 will be inserted into the slot 94 between the second surface 102 and the third surface 104. As such, the projections 96 will reside within the interior of the slot 94. The upturned edge 106 will contact and resist the separation of the guide rail 72 from the rail 74 by virtue of contact with the projections 96. The guide rail 72 can be easily formed in a bending operation. The thin material used for the guide rail 72 enhances the ability to install the register box and to have a minimal weight. Should it be necessary to separate the register box from the joists or from the rails, it is only necessary to apply an outward pulling force to the third surface 104 so as to separate the upturned edge 106 from the respective projections 96.

[0084] The insulated register box and boot rail adapter of the present invention allows the register box to be easily installed and positioned. The configuration of the boot trail adapter allows the register box to slide in desired directions and for desired amounts so as to accommodate the ductwork associated with the register box. The structure of the boot rail adapter of the present invention avoids any penetration of the walls of the register box and avoids any damage to the insulating material used in the register box. The boot rail adapter of the present invention allows the box to be locked onto the rail and the exterior surface. As such, this can resist any inadvertent upward forces which could dislodge the register box from its desired position. The boot rail adapter of the present invention, along with the insulated register box, is of a relatively low cost construction. The simplicity of the boot rail adapter of the present invention requires little or no skill or experience in order to properly install the register box in a desired location.

[0085] After experiments with the register box with the rail adapter of U.S. patent application Ser. No. 15/703,436, it was found that, under certain circumstances, the positioning of the rail and the rail guide could be reversed. This can satisfy certain needs of those it desiring to install the register box of the present invention. In particular, FIG. 11 shows a register box 120 having a plurality of side panels 122 and 124. As with the previous embodiment, a duct will open to the interior of the plurality of side panels 122 and 124. Also, as in the previous embodiment, an insulating material is affixed to the plurality of side panels 122 and 124 and extends inwardly from the side panels. A rail guide 126 defines a slot 128 that extends longitudinally along the rail guide 126. The rail guide is adapted to be affixed to a supporting surface, such as the joists of the previous embodiment. A rail 130 has a section 132 that is received in the slot 128 of the rail guide 126. The rail 130 is affixed to the side panel 122 of the register box 120.

[0086] The rail 130 is slidable relative to the rail guide 126. It can be seen that the rail 130 is affixed to an exterior surface of the side panel 122. In particular, as was described hereinbefore, in association with the rail guide, the rail 130 can also be affixed to the exterior surface of the side panel 122 without fasteners, such as through the use of clinch locks.

[0087] In particular, the rail 130 is affixed to the register box 120 in a similar manner to that of the previous embodiment in which the rail guide is actually affixed to the register box. The rail 130 can include a first rail (shown in FIG. 11) that is affixed to the side panel 122 and a second rail (not shown) that is affixed to an opposite side panel of the register box 120. As with the previous embodiment, the rail guide 126 can include a first rail guide and a second rail guide. It can be seen that the first rail guide 126 receives the first rail 130. Another rail guide located on the opposite side of the register box 120 will receive the second rail therein. The rail 130 includes a surface 134 that is affixed to the side panel 122 and a second surface, such as section 132, that extends transversely outwardly of the first surface 134.

[0088] The rail guide 126 includes a first surface 134 that is adapted to be affixed to the underlying surface. The rail guide 126 also includes a second surface 136 that extends inwardly from a side of the first surface 134. A third surface 138 extends in spaced generally parallel relationship to the second surface 136. The third surface 138 will include an inwardly turned edge (similar to that of the previous embodiment as shown in FIG. 10). The slot 128 of the rail guide 126 is defined by the second surface 136 and the third surface 138. The section 132 of the rail 130 is received between the second surface 136 and the third surface 138.

[0089] The rail 130 includes a plurality of projections 140 that extend outwardly of the section 132. The projection 140 is cooperative with the inwardly turned edge of the third surface 138 of the rail guide 126 so as to lock the rail guide 126 to the rail 130.

[0090] FIG. 12 shows the register box 120 having the duct 142 opening to an interior of the register box 120. FIG. 12 shows that there is a first rail guide 126 and a second rail guide 144 positioned on opposite sides of the register box 120. The register box 120 has the rail 130 affixed to the side panel 122. In the manner shown in FIG. 11, the first rail 130 engages the slot 128 of the rail guide 126. A similar rail, located on the opposite side of the register box 120, will engage with the slot 146 of the second rail guide 144.

[0091] The rail guides 126 and 144 are adapted to be affixed to an exterior surface. With reference to FIG. 6, the rail guides 126 and 144 can be secured to the joists 88 and 90. As such, the rail guides 126 and 144 can be affixed in the same manner that the rails 74 and 80 were affixed to the joists 88 and 90 of FIG. 6. This arrangement will support the register box 120 in a location between the joists 88 and 90. The slidable relationship between the rail 130 and the rail guide 126 allows the register box to be suitably adjusted between the joists 88 and 90.

[0092] In the method of the present invention, with reference to FIGS. 11 and 12, the rail 130 is affixed to the exterior surface of the register box 120. The section 132 of the rail 130 is inserted into the slot 128 of the rail guide 126 such that the rail 130 is secured to the rail guide 126. The rail guide 126 can be fastened to a supporting surface such that the register box 120 extends away from the supporting surface. The method of the present invention allows the section 132 of the rail 130 to slide longitudinally along the slot 128 of the rail guide 126 so as to position the register box in a desired position with respect to the supporting surface. The rail 130 is affixed to the exterior surface of the register box 120 without penetrating the material of the register box 120. This can be accomplished through the use of a clinch lock.

[0093] The step of fastening includes affixing the rail guide 126 to a joist such that the register box 120 is positioned between the first joist 88 and the second joist 90 (as shown in FIG. 6). The first rail guide 126 is affixed to the first and second joist 88 and 90 such that the first rail guide 126 extends between the first and second joists 88 and 90. The second rail guide 144 is affixed to the first and second joists 88 and 90 such that the second rail guide 144 extends between the first and second joists 88 and 90 in parallel relationship to the first rail guide 126. The section 132 of the rail 130 is snap-fit into the slot 128 of the rail guide 126 that such that the rail guide 126 is locked upon the rail 130.

[0094] The foregoing disclosure and description of the invention is illustrative and explanatory thereof. Various changes in the details of the illustrated construction and in the steps of the described method 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.