BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description taken in conjunction with the accompanying Drawings in which:
FIG. 1 illustrates a cross-sectional view of the system of the present invention;
FIG. 2 illustrates a diagram of indentation ring shapes;
FIG. 3 illustrates a diagram of spring shapes;
FIG. 4 is a pictorial illustration of the major ceiling and wall penetration components; and
FIG. 5 illustrates alternate ceiling register configurations of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, there is illustrated a cross-sectional view of a structure showing the system of the present invention, which comprises a method and apparatus for lowering the installed cost and improving the air flow performance of HVAC system ceiling registers 14. Basic system components include an flexible air duct 1 that connects to the supply side of a conventional HVAC system. The open end of flexible air duct 1 then slides over inlet collar 2 of collar plate assembly 3. Flexible air duct 1 is pulled past indentation ring 4 and anchored firmly at the plate portion 5 of collar plate assembly 3 using tie wrap 7 or other suitable fastener devices. This positions the flexible air duct 1 flush with the outer surface of the ceiling 6, producing continuous insulation of the flexible air duct 1 down to the ceiling 6 interface. Rigid metal air duct is applied by slipping it over the crimped portion 8 of collar 2 and attaching it with metal fasteners such as sheet metal screws. The associated air duct insulation is attached in the same manner that flexible duct insulation is attached. In all cases, a suitable sealant such as mastik is applied to all joints to satisfy local building code requirements. Additional insulation protection around the ceiling register 14 is achieved when normal attic or wall insulation 21 is installed or blown in to achieve insulation R values which meet local building code requirements. This provides a second layer of insulation around and on top of the air duct insulation previously installed over the collar plate assembly 3.
Collar plate assembly 3 is anchored to ceiling or wall supports by mounting rails 10 which slide over the edge of plate portion 5 and are attached to the supports at both ends by suitable fasteners such as screws or nails. Ceiling 6 is then installed and properly anchored to the ceiling or wall supports. Access holes 11 are cut through ceiling 6 at each collar plate assembly 3 using the inside surface of collar 2 as a guide for a smooth access hole 11 cut-out. Trim ring 12 is inserted through the access hole 11 and into the collar 2 of collar plate assembly 3 after suitable sealant is applied. This provides a smooth air tight connection from flexible air duct 1, through collar plate assembly 3 into the room interior. Surface coating 13, typically texturing and painting, is applied as required for appearance.
Ceiling register 14 is supplied with at least two locking springs 17 which are manufactured using a material exhibiting good spring characteristics. These locking springs 17 are attached to the ceiling register 14 in a manner such that they extend outward from the periphery of the ceiling register 14 and are compressed when the ceiling register 14 is inserted through access hole 11 and into the collar 2 of collar plate assembly 3. Once surface coating 13 of ceiling 6 is complete, ceiling registers 14 are inserted through access hole 11 and into collar plate assembly 3 until locking springs 17 expand outwardly into indentation ring 4 and lock the ceiling register 14 into position. Indentation ring 4 is positioned during manufacture so that proper locking occurs when ceiling register 14 just makes contact with ceiling 6 interior surface. Locking spring 17 is constructed with sharp-pointed teeth to facilitate a tight grip as the contact point slides up into the indentation ring 4. Indentation ring 4 is fabricated to allow the locking spring 17 teeth to lock in over the range from the beginning of the indentation ring 4 to its maximum depth point. This allows proper locking of the ceiling register 14 with some variations in ceiling 6 and surface coating 13 thicknesses.
Ceiling register 14 contains an air valve that can be manually or electrically positioned (not illustrated) to allow any desired room air flow 20 up to the maximum available 19 from the attached flexible air duct 1. The Air valve is similar to a water valve in function. It contains both a fixed seat 15 and movable seat 16 which is rotated and positioned by threaded assembly 18. They prevent any airflow 20 when the movable seat 16 is positioned in the fully closed position or against the fixed seat 15. The amount of airflow 20 that occurs when the air valve is open is directly proportional to the distance between the fixed seat 15 and the movable seat 16. Manually controlled and electrically controlled (automated) air valves look identical once installed and can be mixed in a given installation to produce the desired air flow 20 into different zones of a structure.
Removal of ceiling register 14 from its locked position within collar plate assembly 3 is facilitated by use of a removal tool 22 which consists of a long rod with a handle and a right angle hook at the end of the rod. The ceiling register is removed by fully opening the valve and inserting removal tool 22 into the valve opening at a position opposite one of the locking springs 17. The removal tool hook is positioned behind the locking spring 17 and sufficient force is applied to compress locking spring 17 enough so that its teeth lose contact with indentation ring 4.
Referring to FIG. 2, there is shown in detail three variations of the indentation ring 4 used with locking spring 17. The left portion of FIG. 2 shows a semicircular indentation. It provides a suitable locking range for the ceiling register of approximately one half its diameter as indicated by the distance between beginning point 23 and apex point 24. This is a commonly available indentation ring. The disadvantages of the semicircular indentation are that tt provides a limited locking range and all gripping force is lost if the locking spring 17 contact point is forced past the apex point 24. The center indentation ring shown in FIG. 2 is a triangular indentation with linear slopes. It provides a suitable lock range for the ceiling register over the linear distance from point 25 to the apex at point 26. Maximum suitable lock range is achieved in this design when the slope of the upper segment, beginning at point 26 is made parallel to the slope of compressed locking spring 17. Advantages of the triangular shaped indentation ring are it provides a wider lock range and presents a constant slope at the locking spring 17 contact point over the whole lock range. The indentation ring shown on the right in FIG. 2 is a discrete stepped indentation. It provides small discrete steps in the lock range. The advantage of the discrete stepped indentation ring is it provides a much wider locking range between beginning point 27 and ending point 28. The disadvantage is it potentially more difficult and costly to manufacture since it must be included in addition to conventional indentation ring 4 which is required as a stop for tie wrap 7.
Referring to FIG. 3, there is shown four variations of design for locking spring 17. The upper set of locking springs designated 17L and 17R contain cut out slot 30 to allow mounting to ceiling register 14 by simply sandwiching each between the edge of the ceiling register board and the upper vertical post of fixed valve seat 15 as shown in FIG. 1. Locking springs 17L and 17R are identical except that the upper portion is bent in opposite directions in the two views. This creates a right and left set of locking springs. Teeth 29 are identical and made very sharp to facilitate their biting into the contact points of indentation ring 4 when ceiling register 14 is properly mounted. When each locking spring 17 is mounted, teeth 29 are spaced an equal distance from the center line of ceiling register 14 to facilitate proper seating of ceiling register 14 into collar plate assembly 3. The angle 33 between the straight vertical section and the upper bent section of locking spring 17 is critical and must be within the range of 45 degrees or less when the ceiling register 14 is properly inserted and installed into register collar 3. This will maintain an adequate angle of attack at the contact points where teeth 29 on locking spring 17 make contact with indentation ring 4 for secure anchoring of the ceiling register 14.
The locking spring design shown in the lower left of FIG. 3 contains two mounting holes 31 for direct attachment along the centerline of a conventional ceiling register using pop rivets, screws or other fasteners. The function of teeth 29 are the same as previously presented. Teeth 29 are spaced an equal distance apart to keep the ceiling register in the center of the collar. The angle of attack at the contact points where teeth 29 make contact with indentation ring 4 should again be 45 degrees or less for proper anchoring of the associated ceiling register.
The locking spring design shown in the lower right of FIG. 3 is another variation of the lower left design showing a single rounded end 32 rather than two sharp teeth. It is easier and less expensive to manufacture and can be used with appropriately designed indentation rings.
Referring to FIG. 4, therein is shown a three dimensional pictorial view of the ceiling or wall penetration components that comprise the current invention. Rigid metal air duct 9 is shown as an alternative to flexible air duct 1. The exploded view shows the mechanical relationships between the primary components. The Collar plate assembly 3 is captured between the mounting rails 10 which are used to attach the combination assembly to the ceiling or wall supports. The mounting rails 10 are typically 24 inches long to accommodate typical support spacings of 16 inches to 24 inches. The mounting rails 10 are completely flat on one surface to limit the gap between the plate 5 and the ceiling 6. Installing the flat side of the mounting rail 10 against the ceiling or wall limits the gap to about one thickness of metal or about 0.025 inches. This eliminates the potential problem with air gaps on cool metal surfaces that can result in unwanted condensation. Even though cut out 11 is controlled by the inner surface of collar 2, the actual resulting hole is often jagged and uneven. Trim ring 12 combined with a suitable sealant provides a rigid air-tight connection between the interior room and the rigid metal air duct 9.
FIG. 5 shows some traditional ceiling register designs that have been augmented with two or more locking springs 17 to allow these registers to be used with the current invention. Round ceiling register 34 is typically made of metal and has been in use for many years. It typically contains three mounting holes that are used with screws to hold the register to a ceiling or wall. These holes have been eliminated since they are no longer needed. Round ceiling register 34 is simply inserted into collar 2 with indentation ring 4 properly positioned.
FIG. 5 also shows a conventional register box 36 that has been augmented with a short indentation segments 38 that match the corresponding locations of the locking springs 17 on rectangular register 35. Conventional register box flange 37 is provided as a ceiling or wall material cut-out guide where cutting is done on the outside surface of the conventional register box flange 37 so that the conventional register box flange 37 can protrude through the ceiling or wall material. Conventional register box 36 may also contain a rectangular indentation ring 4 instead of the short indentation segments 38. Round ceiling register 34 can also be inserted into a conventional square register box 36 that is augmented with an indentation ring 4 or short indentation segments 38. Rectangular register 35 is available in a variety of materials including steel, aluminum and plastic. These registers may be augmented with two or more locking springs 17 to allow them to be used in square or rectangular conventional register boxes 36 that are augmented with an indentation ring 4 or short indentation segments 38. Square registers may also be mounted using these methods.
Patent Application
20080014860
