Abstract
A process for forming an insulated register box includes forming an insulation across the interior surface of a register box, placing a locating collar onto an outer surface of the register box, marking the outer surface of the register box so as to present a representation corresponding to an inner diameter of the collar, separating a portion of the outer surface of the register box from a remainder of the register box corresponding to the marked representation, penetrating the exposed insulation with the collar until an end of the collar opens to an interior of the insulated register box, and positioning the flange against the outer surface of the register box.
Claims
1. A process for forming an insulated register box, the process comprising: forming an insulation across interior surfaces of a register box, the insulation having a thickness; placing a locating collar onto an outer surface of the register box, the locating collar having a collar with a flange extending circumferentially therearound; marking the outer surface of the register box so as to present a representation corresponding to an inner diameter or an outer diameter of the collar; separating a portion of the outer surface of the register box from a remainder of the register box corresponding to the marked representation so as to expose a portion of the insulation; penetrating the insulation with the collar until an end of the collar opens to an interior of the insulated register box; and positioning the flange against the outer surface of the register box.
2. The process of claim 1, the collar having an outer diameter, the flange having an outer diameter, a width of the flange between the outer diameter of the collar and the outer diameter of the flange being greater than the thickness of the insulation.
3. The process of claim 1, the outer surface of the register box having a length dimension or a width dimension, the width dimension greater than an outer diameter of the flange.
4. The process of claim 1, further comprising: affixing the flange around an outer diameter of the collar in location between opposite ends of the collar.
5. The process of claim 4, the step of affixing the flange comprising: inserting an internal diameter edge of the flange into a notch formed around the outer diameter of the collar.
6. The process of claim 1, the step of separating comprising: snipping through a surface of the register box around the marked representation; and removing the snipped surface from the remainder of the register box.
7. The process of claim 1, the step of penetrating the insulation comprising: pushing an end of the collar through the insulation until the flange abuts the outer surface of the register box.
8. The process of claim 1, further comprising: affixing the flange to the outer surface of the register box.
9. The process of claim 8, the step of affixing the flange comprising: applying a fastener to the flange so as to engage with the outer surface of the register box.
10. The process of claim 1, further comprising: applying a mastic around an outer diameter of the flange and to the outer surface of the register box.
11. The process of claim 1, wherein the flange has an inner diameter received within a notch formed around a circumference of the collar, process further comprising: fitting an edge of the outer surface of the register box into the notch of the collar.
12. A locating collar for use with an insulated register box, the locating collar comprising: a collar having a first end and a second end, said collar having an outer diameter; and a flange affixed to the outer diameter of said collar, said flange radiating outwardly of said collar, said flange having an outer diameter greater than the outer diameter of the collar, said flange positioned in a location between the first end and the second end of the collar, the second end of said collar adapted to extend through insulation of the insulated register box such that an interior of said collar opens to a cavity within an interior of the insulated register box.
13. The locating collar of claim 12, wherein a distance between the outer diameter of said collar and the outer diameter of said flange is greater than a thickness of the insulation in the insulated register box.
14. The locating collar of claim 13, wherein the outer diameter said flange is less than a width of a surface of the insulated register box.
15. The locating collar of claim 13, said collar have a notch formed therearound, said flange having an inner diameter received in the notch of said collar.
16. An assembly comprising: a register box having an outer surface and an insulating material applied to an inner surface of said register box, the insulating material having a thickness, the register box having an interior cavity; and a collar having a flange affixed thereto so as to radiate outwardly of said collar, the flange bearing against the outer surface of said register box, said collar having a portion extending through the thickness of the insulating material so as to have an end opening to the interior cavity of said register box, said collar having another portion extending outwardly of the outer surface of said register box.
17. The assembly of claim 16, said flange being affixed to the outer surface of said register box.
18. The assembly of claim 17, said collar having a notch extending circumferentially therearound, the flange having an inner diameter received within the notch, the outer surface of said register box having an edge received within the notch.
19. The assembly of claim 17, further comprising: a mastic applied to an outer diameter of the flange and the outer surface of the register box so as to form an air-tight seal therebetween.
20. The assembly of claim 17, wherein an outer diameter of the flange and an outer diameter of the collar define a distance that is greater than a thickness of the insulating material, the flange having an outer diameter less than a width of the outer surface of said register box.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0061] FIG. 1 is a side elevational view of the locating collar in accordance with the teachings of the present invention.
[0062] FIG. 2 is a plan view showing the locating collar of the present invention.
[0063] FIG. 3 is a plan view showing the locating collar of the present invention as placed upon an outer surface of a register box.
[0064] FIG. 4 illustrates a marking carried out on the outer surface of the register box.
[0065] FIG. 5 is a side elevational view showing the placement of the locating collar upon the outer surface of the register box.
[0066] FIG. 6 is a cross-sectional view showing the locating collar as placed upon the outer surface of the register box.
[0067] FIG. 7 is a plan view showing a portion of the outer surface of the register box that is removed so as to expose the insulation thereunder.
[0068] FIG. 8 is a cross-sectional view showing the insertion of the locating collar of the present invention through the insulation of the register box of the present invention.
[0069] FIG. 9 is a detailed cross-sectional view showing the engagement between the flange of the locating collar and the edge of the outer surface of the register box within a notch formed on the locating collar.
[0070] FIG. 10 is a side cross-sectional view showing the use of the locating collar of the present invention in conjunction with a sidewall of the register box.
DETAILED DESCRIPTION OF THE INVENTION
[0071] FIG. 1 shows locating collar 10 in accordance with the preferred embodiment of the present invention. Locating collar 10 includes a collar 12 having a first end 14 and a second and 16. The collar has an outer diameter D.sub.2. A flange 18 is affixed to the outer diameter D.sub.2 of the collar 12. The flange 18 extends radially outwardly of the collar 12. The flange 18 has an outer diameter D.sub.1. Diameter D.sub.1 is greater than the outer diameter D.sub.2 of the collar 12. The flange 18 is positioned in a location between the first end 14 and the second end 16 of the collar 12. The second end 16 is adapted to extend through the insulation of the register box such that an interior of the collar 12 opens to a cavity within an interior of the register box (to be described hereinafter).
[0072] A distance between the outer diameter D.sub.2 of the collar 12 and the outer diameter D.sub.1 of the flange is greater than a thickness of the insulation in the insulated register box. The outer diameter D.sub.1 of the flange 18 is less than a width of a surface of the insulated register box. The flange 18 will have an inner diameter that is received within a notch 20 formed circumferentially in the collar 12.
[0073] In FIG. 1, it can be seen that there is a ridge 22 that is formed adjacent to the first end 14 of the collar 12. The second end 16 of the collar 12 will be sufficiently sharp so as to allow the second end 16 to dig through the insulation of the register box. The flange 18 has a generally annular configuration. The bottom surface 24 of the flange 18 is adapted to bear against the outer surface of the register box.
[0074] FIG. 2 is a plan view of the locating collar 10 of FIG. 1. In particular, it can be seen that the collar 12 has an annular configuration with an open interior 26. Open interior 26 can be used to connect to the ductwork of an HVAC system. Ultimately, the open interior 26 will open to the interior cavity of the insulated register box (as will be described hereinafter). FIG. 2 shows that the flange 18 has an annular configuration. The inner diameter of the flange 18 will be engaged with a notch formed circumferentially around the collar 12. The flange 18 has markings 28 on a surface thereof. These markings 28 can be in various positions and can be of various numbers, but are used so as to designate proper locations for inserting screws, or other fasteners, for the purposes of joining the flange 18 to the outer surface of the register box.
[0075] FIG. 3 illustrates the locating collar 10 as positioned on the outer surface 30 of register box 32. FIG. 3 shows that the outer surface 30 of register box 32 has a width W.sub.2. Importantly, the locating collar 10 has the collar 12 and the flange 18 configured in the manner described hereinbefore in connection with FIGS. 1 and 2. Importantly, for the purposes of the present invention, the outer diameter D.sub.1 of the flange 18 will be less than the width W.sub.2 of the outer surface 30 of register box 32. Ultimately, the width W.sub.1 (as shown in FIG. 1) of the flange 18 will be at least as wide as or wider than the insulation within the interior of the register box 32. As such, when the locating collar 10 is placed upon the outer surface 30 of the register box 32, it can be assured that the collar 12 will always be positioned directly above the internal cavity of the register box. Since the width of the insulation will be equal to or less than the width W.sub.1 of the flange 18, this placement is assured. Also, since it is important to place the flange 18 within the width W.sub.2 of the register box 30, the accurate placement of the locating collar 12 is assured. Suitable instructions can be provided to the installer to maintain the outer diameter D.sub.1 of the flange 18 within the perimeter of the register box 32. As such, regardless of the placement of the locating collar 10 on the outer surface 30 of the register box 32, it is assured that the collar 12 will always reside over the internal cavity of the register box. As such, the configuration shown in FIG. 3 will allow the installer to adapt the locating collar 10 to the ductwork of the HVAC system. Also, the locating collar 12 can have various dimensions of the outer diameter D.sub.1 of the flange 18 and the outer diameter D.sub.2 of the collar 12. As such, if smaller ductwork is involved with the HVAC system, a collar can be chosen to match the diameter of such ductwork. Similarly, if a smaller register box is employed with a smaller amount of insulation, a suitable flange 18 can be utilized. This provides a great advantage to workers in that the register box 32 and the locating collar 10 can be supplied separately. The installer only has to choose the appropriate collar 12 and the appropriate flange 18 and choose the appropriate location on the outer surface of the register box 32 in order to properly install the locating collar 10 in the manner to be described hereinafter.
[0076] FIG. 4 shows that the further step in the present invention. It can be seen that in FIG. 3 that the locating collar 12 has an inner diameter 34. FIG. 4 shows that the installer can use the locating collar 12 and its inner diameter 34 as a template for marked representation 36 of this inner diameter (or the outer diameter) of the locating collar 34. As such, the marked representation 36 will be indicative of the desired location of the collar 34 with respect to the outer surface 30 of the register box 32. This marked representation will correspond in a location which avoids any unnecessary removal of excess insulation from the interior of the register box. As a result, the proper R-value of the insulation is preserved. Ultimately, after the marked representation 36 is achieved, the worker can use snippers to cut around this marked representation 36 so as to remove the metal material of the register box 30 and expose the insulation therebelow (in the manner described hereinafter). Since the collar 12 is somewhat flexible, accurate cutting around the marked representation 36 is not critical to the installation of the locating collar 10.
[0077] FIG. 5 shows a side view of the register box 32. Register box 32 includes the outer surface 30 at a top thereof. Register box 32 also includes end surfaces 40 and 42 and a side surface 44 extending between the end surfaces 40 and 42. Another side surface (identical decide surface 44) will be formed on the opposite side of the register box 32 (not shown). A flange member 46 extends downwardly from the bottom 48 of the register box 32. Flange member 46 will define an opening 50 at the bottom 48 of the register box 32.
[0078] As can be seen in FIG. 5, the locating collar 10 is positioned on the outer surface 30 of the register box 32. Specifically, the second end 16 will bear against the outer surface 30. Flange 18 extends radially outwardly of the outer diameter of the collar 12. In this position, the installer can easily extend a pen (or other marking device) through the open end 52 of collar 12 so as to prepare the marked representation 36 (as shown in FIG. 4). After this marked representation is carried out, the locating collar 10 can be lifted from the outer surface 30 of the register box 32.
[0079] FIG. 6 shows the register box 32 as having insulation 54 on an interior thereof. Insulation 54 will extend across the end wall 42, the end wall 40, and the outer surface 30. As such, the insulation 54 will define an interior cavity 56 in the interior of the register box 32. The locating collar 10 is illustrated as positioned on the outer surface 30. The outer surface 30 will be steel, aluminum, or other material, upon which the insulation 54 is applied. In the present invention, the insulation 54 is a foamed polymeric material. A suitable form can be placed into the interior of the register box 32 so as to properly form the foamed polymeric material around the inner surfaces of the register box 32. The insulation 54 will have a thickness T.
[0080] In FIG. 6, the locating collar 10 has the flange 18 radiating outwardly from the collar 12. The portion 58 of the flange 18 will have a width greater than the thickness T. As such, no matter where the locating collar 10 is placed on the outer surface 30, as long as the outer diameter D.sub.1 of the flange 18 is within the width D.sub.2 of the outer surface 30, the width D.sub.1 associated with portion 58 of flange 18 will assure that the marked representation (taken from the inner diameter of the collar 12) will always be within the area of the insulation 54 at the outer surface 30 and will not be above the insulation 54 at the end walls 40 and 42. As such, this assures that the collar 12 will always be positioned correctly and directly above the interior cavity 56 of the register box 32.
[0081] FIG. 7 shows the outer surface 30 of register box 32 after the marked representation has been snipped. In particular, after the snipping of the marked representation 36 (as that shown in FIG. 4) has occurred, there will be a metallic disc that is formed. This metallic disc can be removed from the circular area 60 so as to expose the insulation 54 therebelow. The snipped circular area 60 will have a diameter generally corresponding to the diameter D.sub.2 of the locating collar 10.
[0082] FIG. 8 shows the next step for installing the locating collar 10 into the register box 32. In particular, since the end 16 of locating collar 12 is relatively sharp, it can be inserted through the snipped circular area 60 (as shown in FIG. 7) and pushed downwardly so as to penetrate the insulation 54. This can be achieved by downward force applied on the first end 14 of collar 12 and with minor rotations applied to the collar 12. Ultimately, this insertion process will continue until the flange 18 bears against the outer surface 30 of the register box 32. This assures that the second end 16 is now located within the interior cavity 56 of the register box 32 and that the insulation bears tightly against the out diameter of the collar 12. Once this positioning is achieved, a circular disc 62 of the insulation 50 can be pushed out of the second end 16 of the collar 12 and removed from the open end 50 of the register box 32. As such, the open interior 34 of the collar 12 will communicate with the interior cavity 56 of the register box 32.
[0083] Once this installation process is achieved, a fastener 64 can be applied to the flange 18 so as to affix the flange 18 against the outer surface 30 of the register box 32. The fastener 64 can be in the nature of a screw. The screw can be applied through the marked areas 28 (as shown in FIG. 2). As such, the flange 18 can be securely mounted onto the outer surface 30 so as to cover the snipped-out circular area 60. A mastic 66 can be applied to the outer diameter of the flange 18 onto the outer surface 30 of the register box 32. The mastic 68 can also be applied between the inner diameter of the flange 18 and the outer diameter of the collar 12. Mastic beads 66 and 68 assure an airtight sealing relationship between the locating collar 10 and the outer surface 30 of the register box 32. The mastic can be in the nature of a UL 181 sealant.
[0084] Importantly, in the configuration shown in FIG. 8, there is an improved sealing relationship between the locating collar 10 and the register box 32. The insertion of the collar 12 through the insulation 54 by pushing and rotating will assure a very tight sealing relationship between the outer diameter of the collar 12 and the corresponding surfaces of the insulation 54. This will ultimately be a virtually airtight seal. This manner of installation avoids any unnecessary removal of insulation 54, assures a tight fit, and improves the insulation R-values of the insulation 54. Additionally, since the flange 18 is secured to the outer surface 30 and since the inner diameter of the flange 18 is in a close sealing relationship with the outer diameter of the collar 12, this further improves the air-tight qualities of the insulation. Since the flange 18 is secured to the outer surface 30 through the use of fasteners 64, this assures that the locating collar 10 cannot be dislodged from the register box 32 during installation or movement. Additionally, and furthermore, the application of the mastic beads 66 and 68 to the corresponding surfaces of the outer surface 30, the flange 18 and the collar 12 further assures the air-tight relationship between the locating collar 10 and the register box 32. As such, the locating collar 10 serves as a measuring device, a template, and a mounting flange. Only a minimal amount of insulation is removed. The flange 18 serves as an additional fire barrier. As such, the locating collar 10 assures a better quality product, a better insulated product, and a more easily installed product.
[0085] FIG. 9 shows a unique aspect of the present invention. In FIG. 9, it can be seen that the locating collar 10 has collar 12 with a notch 70 formed circumferentially around the outer diameter of the locating collar 12. The flange 18 has its inner diameter 72 received within this notch 70. Additionally, and furthermore, it can be seen that the outer surface 30 of the register box has an edge 74 also received within a notch 70. This essentially creates a “snap-fit” relationship between the locating collar 10 and the metal material of the outer surface 30 of the register box 32. This once again further improves the sealing relationship between the flange and the surfaces of the register box. This installation provides a tactile and somewhat audible presentation to the installer that the locating collar 10 has been properly installed. FIG. 9 further shows the tight sealing relationship between the end 16 of the collar 12 and the insulation 54.
[0086] FIG. 10 further shows an alternative arrangement of the present invention. In FIG. 10, it can be seen that the locating collar 80 is positioned against an end side 82 of the register box 84. As such, the end side 82 will actually be the “outer surface 30” in this embodiment. In certain HVAC systems, it will be important to install the locating collar in this end side 82 (or into any of the other sides of the register box). As such, locating collar 80 is applicable to such an installation. Ultimately, the locating collar 80 includes collar 86 and flange 88. As with the previous embodiment, the flange 88 will have an outer diameter D.sub.1. The collar 86 will have an outer diameter D.sub.2. The distance between the outer diameter D.sub.2 of the collar 86 and the outer diameter D.sub.1 of the locating collar 88 will be greater than the thickness of the insulation 90 on the inner surfaces of the register box 82. In this embodiment of the present invention, similar steps can be carried out (as in the previous embodiments) such that the end 92 of the collar 86 will resides though as to open to the interior cavity 94 of register box 82.
[0087] 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.
