REGISTER BOX ADAPTABLE TO DUCTWORK OF AN HVAC SYSTEM

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 wall extending in generally transverse relation to the plurality of side panels, and an expandable polymeric material affixed to an inner side of the side panels and across the wall. The wall has a plurality of concentric circular areas cut into the wall. Each of the concentric areas is formed of a first partial circle having ends in spaced relation to a second partial circle. The circular area can be removed from the wall so as to allow a user to cut through the polymeric material at the wall so as to form a hole opening to an interior of the register box. This hole can receive a collar therein. The collar can be connected to the HVAC system.

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 wall extending generally transverse to the plurality of side panels, the plurality of side panels defining an opening opposite the wall, the wall having a plurality of concentric circular areas cut into the wall; and an expandable polymeric material affixed to an inner side of each of the plurality of side panels and across at least a portion the wall.

2. The register box of claim 1, wherein each of the plurality of concentric circular areas comprise a first partial circle having ends in spaced relation to a second partial circle.

3. The register box of claim 2, wherein the ends of the first and second partial circles are spaced apart equally for each of the plurality of concentric circular areas.

4. The register box of claim 1, wherein the plurality of concentric circular areas are at least three circular areas of differing diameters.

5. The register box of claim 1, wherein each of the plurality of concentric circular areas is formed centrally of the wall.

6. The register box of claim 1, the body being formed of thirty gauge galvanized sheet steel.

7. The register box of claim 1, wherein at least one of the plurality of concentric circular area is selectively removable, the register box further comprising: a collar affixed to the body, said collar extending through the selectively removed at least one of the plurality of concentric circular areas and through the expandable polymeric material so as to open to an interior of the body.

8. A method for forming an insulated register box, the method comprising: forming a sheet of metallic material into a generally box shape having a plurality of side panels and a wall extending across an area defined by the plurality of side panels, the plurality of side panels defining an opening opposite the wall; cutting a plurality of concentric circular areas into the wall; and injecting an expandable polymeric material into an interior of the generally box shape, the expandable polymeric material adhering to the plurality of side panels and to the wall.

9. The method of claim 8, wherein the step of cutting comprises: laser or plasma cutting the plurality of concentric circular areas into the wall.

10. The method of claim 8, wherein the step of cutting comprises: cutting a first circular area into the wall; and cutting a second circular area into the wall, the first circular area having a diameter less than the diameter of the second circular area.

11. The method of claim 10, wherein the step of cutting the first circular area comprises: cutting a first partial circular area into the wall, the first partial circular area having a first end and a second end; and cutting a second partial circular area in the wall, the second partial circular area having a first end and a second end, the first end of the second partial circular area being spaced from the first end of the first partial circular area, the second end of the second partial circular area being spaced from the second end of the second partial circular area.

12. The method of claim 8, further comprising: removing one of the plurality of concentric circular areas from the wall so as to expose the expanded polymeric material at the wall; and cutting a hole in the expanded polymeric material, the hole opening to an interior of the register box.

13. The method of claim 12, wherein the hole has a diameter approximately equal to a diameter of the removed one of the plurality of concentric circular areas.

14. The method of claim 12, further comprising: placing a collar into the cut hole and through the removed one of the plurality of concentric circular areas such that the collar has one end positioned exterior of the register box and an opposite end interior of the register box.

15. The method of claim 12, the step of removing comprising: folding an edge of one of the plurality of concentric circular areas back-and-forth until the one of the plurality of concentric circular area separates from the wall.

16. The method of claim 8, further comprising: placing a sheet or panel over an exterior of the wall and over the plurality of concentric circular areas prior to and during the step of injecting the expandable polymeric material; and removing the sheet or panel after the expandable polymeric material has expanded.

17. The method of claim 8, the step of cutting comprising: cutting the plurality of concentric circular areas entirely through a thickness of the wall.

18. A method of connecting a register box to a duct of an HVAC system, the method comprising: forming the register box having a plurality of side panels and a wall extending across the plurality of side panels, the register box having an expandable polymeric material residing against the plurality of side panels and against the wall; cutting a plurality of concentric circular areas into the wall; removing at least one of the plurality of concentric circular areas from the wall so as to expose a portion of the expandable polymeric material residing against the wall so as to define a hole in the wall opening to the expandable polymeric material; cutting through the exposed portion of the expandable polymeric material so as to open to an interior of the register box; inserting a collar through the hole in the wall and into the cut exposed portion of the expandable polymeric material; and connecting the collar to the duct of the HVAC system.

19. The method of claim 18, wherein the removed at least one of the plurality of concentric circular areas has a diameter approximately equal to the diameter of the collar, the collar having a diameter approximately equal to a diameter of the duct of the HVAC system.

20. The method of claim 18, the step of cutting the plurality of concentric circular areas comprising: laser or plasma cutting the plurality of concentric circular areas into the wall, each of the plurality of concentric circular areas being a pair of partial circles residing in spaced relation to each other.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0051] FIG. 1 is an upper perspective view of the register box in accordance with the teachings of the present invention.

[0052] FIG. 2 is a side elevational view of the register box in accordance with the teachings of the present invention.

[0053] FIG. 3 is a bottom view of the register box in accordance with the teachings of the present invention.

[0054] FIG. 4 is a cross-sectional view showing the register box in association with the present invention.

[0055] FIG. 5 is an upper perspective view showing the circular area at the top of the register box of the present invention.

[0056] FIG. 6 shows a cross-sectional view of the register box of the present invention with the collar installed.

[0057] FIG. 7 is a side elevational view of the register box of the present invention with the collar installed.

[0058] FIG. 8 is a bottom view of the register box the present invention with a different-sized collar installed therein.

DETAILED DESCRIPTION OF THE INVENTION

[0059] FIG. 1 shows the register box 10 in accordance with the teachings of the present invention. The register box 10 includes a body 12 having a plurality of side panels 14, 16, 18 and 20 arranged in a generally rectangular or square configuration. Side panels 16 and 20 extend between side panels 14 and 18. A wall 22 extends a generally transverse relation to the plurality of side panels 14, 16, 18 and 20. A plurality of concentric circular areas 24 is cut into the wall 22. The plurality of concentric circular areas 24 defines a first circular area 26, a second circular area 28 and a third circular area 30. Each of the circular areas 26, 28 and 30 is laser or plasma cut into the wall 22. Each of the circular areas 26, 28 and 30 has a different diameter. These cut circular areas extends through the thickness of the wall 22. Uncut spaces 32 and 34 are formed between ends of the partial circular areas of each of the concentric circular areas 26, 28 and 30. In particular, it can be seen that circular area 26 has a first portion that is separated by the second portion by the spaces 32 and 34. Similarly, the circular area 28 has portions that are separated by the uncut spaces 32 and 34. The circular area 30 has portions that are separated by the uncut spaces 32 and 34. The uncut spaces provide a place whereby each of the partial circles can be bent back and forth so as to separate from the wall 22 (in the manner to be described hereinafter). The different diameters of the circular areas 26, 28 and 30 allows the register box 10 of the present invention to be adaptable to various collars received therein and therethrough. These collars are in the nature of collars that can be connected to the ductwork of the HVAC system.

[0060] FIG. 2 shows a side view of the register box 10 of the present invention. In particular, FIG. 2 shows the side panel 14. Side panel 14 extends transverse to side panels 16 and 20. A flange 40 extends downwardly from the bottom 42 of the register box 10. Flange 40 defines an opening at the bottom 42 opposite the wall 22.

[0061] FIG. 3 shows the bottom view of the register box 10 of the present invention. In particular, in FIG. 3, the expanded polymeric material 44 within the interior of the register box 10 is particularly illustrated. This expanded polymeric material 44 will reside against the inner surface of the wall 22 and against the inner surfaces of the side panels 14, 16, 18 and 20.

[0062] In particular, FIG. 3 shows that the side panel 14 has a flange 46 extending inwardly therefrom. Flange 40 extends downwardly from an edge of flange 46 opposite the side panel 14. Similarly, side panel 16 has a flange 48 that extends inwardly therefrom. Another flange 50 will extend outwardly from the edge of flange 48 opposite to side panel 16. The side panel 18 has a flange 50 that extends inwardly therefrom. Another flange 52 will extend outwardly from the edge of flange 50 opposite to the side panel 18. Side panel 20 has a flange 54 extending inwardly therefrom. Another flange 56 will extend outwardly from flange 54 at an edge opposite the side panel 20. Flanges 40, 50, 52 and 56 define the opening 58. Opening 58 will be opposite to the concentric circular areas 24 on the wall 22. As will be described hereinafter, the expandable polymeric material 44 will reside against the side panels 14, 16, 18 and 20 and will be generally retained within the area of the flanges 40, 50, 52 and 56.

[0063] FIG. 4 shows the insulated register box 10 of the present invention with the expandable polymeric material 44 positioned within the interior of the register box 10. The void 60 is formed in the interior of the register box of the present invention in the manner described in conjunction with U.S. Patent Application Publication No. 2018/0363942 of the present Applicant. As can be seen, the expandable polymeric material is generally aligned with the flanges 50 and 56. The expandable polymeric material 44 will extend a similar distance away from the inner surface of the wall 22.

[0064] FIG. 4 shows the feature of the present invention during the manufacture of the insulated register box 10. Since the plurality of concentric circular areas 24 is cut entirely through the thickness of the wall 22, there is a possibility that when the expandable polymeric material expands, it could force its way through these concentric circular areas. This could bend or distort the wall 22. As such, a sheet or panel 62 is positioned and retained over the wall 22 during the introduction and expanding of the expandable polymeric material 44 within the register box 10. This will maintain the circular areas intact and in a generally planar configuration. Forces can be applied to the sheet or panel 62 so as to resist the forces resulting from the expanding of the polymeric material 44. It is also possible that a sticker can be the sheet 62. This sticker can have circular lines corresponding to be circular areas that have been cut into the wall 22. This type of sticker can serve to retain the circular areas in a planar configuration and can also allow a worker to properly envision the necessary areas to cut in order to expose the cut circular areas and remove the cut areas from the register box 10. Various other configurations of sheet or panel 62 can also be used so as to achieve this particular purpose.

[0065] FIG. 5 illustrates the wall 22 during the removal of a circular area 70. In particular, FIG. 5 shows the concentric circular areas 26, 28 and 30. Concentric circular area 26 defines the circular area 70 therein. The circular area 70 is of thirty gauge galvanized stainless steel. Importantly, each of the concentric circular areas 26, 28 and 30 is sized so as to fit the various diameters of ductwork associated with HVAC systems. The concentric circular area 26 is for a smaller ducts. Concentric circular area 28 is formed intermediate size ducts. Concentric circular area 30 is for larger ducts. Importantly, so as to connect with the ductwork, the circular areas associated with these concentric circles circular areas 26, 28 and 30 can be selectively removed so as to allow a collar to be inserted therein (in the manner described hereinafter).

[0066] In FIG. 5, it can be seen that circular area 30 has a first partial circle 72 and a second partial circle 74. End 76 of partial circle 72 is spaced from end 78 of partial circle 74. Similarly, end 80 of partial circle 72 is separated from end 82 of partial circle 74. The similar spacing occurs with respect to the other concentric circular areas 26 and 28. The spacing allows the particular circular cut area to be folded back-and-forth so as to separate the circular cut area from the remainder of the wall 22. FIG. 5 shows circular cut 70 as being folded in this manner. It is only necessary to grab an edge of this cut circular cut, lift it, and fold it back-and-forth until the circular cut area is separated. This will expose the expandable polymeric material 44 located on the inner side of wall 22.

[0067] FIG. 6 shows a further step in the process of the present invention. In FIG. 6, the removed circular area 70 has been separated from the remainder of the wall 22 such that the expandable polymeric material 44 is exposed. A knife, or other device, can be used so as to saw through the expandable polymeric material 44 and to follow the outline of the circular area 26. This will allow the expandable polymeric material 44 in the interior of the circular area 26 to be removed and to expose the void 60 on the interior of the register box 10. Importantly, the configuration of the present invention makes it easy for a worker to create this hole in the expandable polymeric material 44. The edges of the cut circular areas can serve as a guide. As such, it is only necessary for a worker to extend a knife, or similar device, downwardly through the expandable polymeric material 44 and saw around the perimeter of the opening left by the removal of the circular area 70. As such, this will open area 84 within the register box 10. A collar 86, having a size corresponding to the diameter of the circular area 26, can then be inserted into the opening 88. As a result, collar 86 will have a portion 90 residing against the expandable polymeric material 44 and another portion 92 extending outwardly of the register box 10. Portion 92 can be engaged with the ductwork of an HVAC system. A sealant 94 can be applied at the area of the juncture between the collar 86 and the wall 22. The pliability of the expandable polymeric material 44 will ensure a tight seal between the exterior surfaces of portion 90 and the expandable polymeric material.

[0068] FIG. 7 shows an exterior view of the completed register box 10 in accordance with the present invention. It can be seen that there is a cylindrical collar 86 that extends upwardly from the wall 22 of the register box 10. The body 12 of the register box 10 will receive the portion 90 of the collar 86. Collar 86 is adapted to be affixed to the duct of the HVAC system.

[0069] FIG. 8 shows the register box 10 is used in association with a wider diameter collar 98. In this configuration, the concentric circular area 30 is removed (along with the concentric areas 28 and 26) so as to define a larger hole opening to the expandable polymeric material 44. As such, a wide diameter collar 98 is accommodated through the expandable polymeric material 44 and through the opening in the wall 22. This larger duct 98 will open to the void 60 within the interior of the body 12 of the register box 10. The expandable polymeric material 44 will envelop the exterior of the portion 100 of the wide diameter duct 98 so as to create a seal therewith.

[0070] The present invention offers a wide variety of advantages over the prior art. In particular, the present invention makes the register box of the present invention adaptable to ductwork of various HVAC systems. As such, it is not necessary for a customer to specify, with precision, the diameter of the ductwork of such an HVAC system. Furthermore, a common register box can be supplied for installation with various systems. Since the cut areas in the wall 22 of the present invention are matched to the diameter of the collar and the associated ductwork of the HVAC system, a much better seal is created when installed. Adaptation between unequal diameters is not required within the present invention. The present invention can be customized to the particular HVAC system and ductwork associated therewith.

[0071] The unique configuration of the present invention allows the cut circular areas to serve as a guide for the cutting of the expandable polymeric material when forming the hole opening to the void in the interior of the register box. This guide makes it easier for unskilled workers to form the proper diameter of the hole that accommodates the collar. As such, proper cuts are automatically achieved because of the configuration of the present invention. This allows unskilled workers to adapt the register box of the present invention to the various sizes of ductwork of HVAC systems.

[0072] The present invention can provide a smaller footprint for these storage, transportation of the register box. In the prior art, the collar has been automatically affixed to the register box. However, in the present invention, the collar can be shipped separate from the register box. The register box can easily be stacked one upon the other. This creates a very minimal footprint. The collars can be stored elsewhere for easy shipping. The installation of the collar within the register box can be carried out on-site with little or no difficulty.

[0073] The expandable polymeric material that is used on the interior of the register box of the present invention is very energy efficient. The expandable polymeric material can be easily installed. This is particularly true since the expandable polymeric material against the inner surface of the wall does not need to be pre-formed. As described in the previous applications to the present Applicant, the expandable polymeric material that is used for the installation of the register box of the present invention can be simply injected into the interior of the register box so as to expand around a plug placed in the interior. The expandable polymeric material minimizes air loss since it covers all surfaces on the interior of the register box. This will improve the insulation rating of the register box. Expandable polymeric material is fire resistant and compliant with national building codes. This expandable polymeric material avoids the use of fibrous insulation and, as such, will improve the health and safety of the workers.

[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 appended 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.