Abstract:
A forced air vent register that is adapted to house pieces of flooring identical to the surrounding flooring. The register is of sufficient structural strength to withstand distortion under considerable forces.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to ventilation heating and cooling and more particularly to a forced air vent register that can be made to match the surrounding environment. 
     The normal practice when installing ceramic floor tile is to lay the tile up to the edges of the register opening and then to install a conventional metal register over or in the opening such that the flange of the register overlaps the ceramic tile about the periphery of the register opening and transitions or “dresses” the tiled floor into the register opening. The process is similar whether the flooring material is wood, carpeting, ceramic tile, linoleum, laminate, or stone such as granite, marble or slate. 
     In upscale residential or commercial buildings, flooring commonly uses expensive hardwoods or tile such as ceramic, slate, marble, granite, laminate, etc. Coordinating the forced air vent registers or grilles to the flooring is desirable but difficult because of the limited styles of registers. Fabrication of matching wood grilles is possible because of wood&#39;s structural characteristics but because of the open space required for air passage, wooden registers have limited strength. Although wooden grilles are available at a premium price, they are only readily available in domestic woods such as oak, which will not coordinate with the flooring if the flooring is of an exotic wood or has contrasting colored accents in the area of the register opening. This mismatch between the floor covering and the registers detracts from the area&#39;s aesthetic appeal. Additionally, wooden constructed registers are usually “fixed” and do not have the capability to adjust the air flow through the register. 
     Fabrication of a grill solely from ceramic tile is impractical because the brittle nature of ceramic tile will not accommodate the application of unsupported weight. Hiding or disguising registers in a ceramic tile floor is often impossible as the available registers are of painted or plated steel construction and stand out from the flooring material. 
     Another problem with existing registers is that they tend to sit slightly above the flooring which emphasizes the visual obtrusiveness of the register. These registers also function as a lip on which to stub toes or damage footwear. 
     Fabrication of matching registers for each separate type of flooring in all the applicable sizes would be impractical and would result in prohibitively expensive registers. 
     SUMMARY OF THE INVENTION 
     In accordance with the invention, an improved air vent register is provided which is adapted to sit flush with the surrounding flooring and to allow flooring pieces to be installed into the grille thereby making a perfect match for the floor. 
     Accordingly, it is an object of the present invention to provide an improved forced air vent register that can withstand the application of considerable unsupported weight without deformation or structural damage. 
     It is a further object of the present invention to provide an improved forced air vent register that can house sections of flooring so as to visually appear to be a continuation of the floor. 
     It is yet another object of the present invention to provide an improved forced air vent register that resides flush with the top surface of the existing floor and which allows for a full range of air flow adjustments. 
     It is still a further object of the present invention to provide an improved forced air vent register that is easily removed for cleaning and retrieval of objects. 
     It is yet a further object of the present invention to provide an improved forced air vent register that houses and supports cut pieces of tile, stone, hardwood and laminate floor covering thus coordinating the register to the surrounding floor covering. 
     It is yet still a further object of the present invention to provide an improved forced air vent register that houses and supports cut pieces of flooring, resides flush with the top surface of the existing floor and has a mechanism capable of adjusting the air flow through the register. 
     The subject matter of the present invention is particularly pointed out and distinctly claimed in the concluding portion of this specification. However, both the organization and method of operation, together with further advantages and objects thereof, may best be understood by reference to the following description taken in connection with accompanying drawings wherein like reference characters refer to like elements. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of the preferred embodiment of the forced air vent register in disassembled, partially exploded form; 
     FIG. 2 is a perspective view of the preferred embodiment of the forced air vent register shown assembled; 
     FIG. 3 is an enlarged cross sectional view of the preferred embodiment of the forced air vent register taken through line  3 — 3  of FIG. 2; 
     FIG. 4 is an enlarged cross sectional view of the preferred embodiment of the forced air vent register taken through line  4 — 4  of FIG. 2; 
     FIG. 5 is a diagrammatic perspective view of a subfloor housing a forced air vent; 
     FIG. 6 is a diagrammatic perspective view of the border support of the preferred embodiment of the forced air vent register installed around a forced air vent opening; 
     FIG. 7 is a diagrammatic perspective view of a tiled subfloor and a border support with tile pieces installed; 
     FIG. 8 is an exploded diagrammatic perspective view of a tiled subfloor, a tiled installed border support with a air adjustment plate installed and a tiled louver cradle; 
     FIG. 9 is an enlarged cross sectional view of the preferred embodiment of the forced air vent register as in FIG. 4 with tile installed; 
     FIG. 10 is a perspective view of a tiled floor with the preferred embodiment of the forced air vent register installed; 
     FIG. 11 is a perspective view of an alternate embodiment of the forced air vent register in disassembled form; 
     FIG. 12 is an enlarged cross sectional view of the assembled alternate embodiment of the forced air vent register along line  112 — 112  of FIG. 11; 
     FIG. 13 is an enlarged cross sectional view of the assembled alternate embodiment of the forced air vent register taken along line  113 — 113  of FIG. 11; and 
     FIG. 14 is an enlarged cross sectional view of the assembled alternate embodiment of the forced air vent register as in FIG. 13 with tile installed. 
    
    
     DETAILED DESCRIPTION 
     The apparatus according to a preferred embodiment of the present invention comprises a forced air vent register and more specifically a substrate or backbone of a register that is adapted to receive matching inserts of the surrounding flooring. 
     FIG. 1, a perspective view of the forced air vent register when disassembled according to the present invention, illustrates the following three components that make up the preferred embodiment: border support  2 ; air flow adjustment plate  13 ; and louver cradle assembly  5 . A portion of the FIG. 1 view is exploded to further illustrate components of the register. 
     A rectangular border support  2  is formed from U-shaped channels with bottom  8 , exterior side walls  10  and interior side walls  12 , the interior side walls defining a border opening  14 . A flange  6  projects normally from the bottom of the interior side walls. The bottom of the border support has beveled holes  7  defined therein to accept screws or nails, allowing for the countersinking of tapered heads on the screws or nails. 
     Air flow adjustment plate  13  is suitably a thin rectangular plate with plural slit openings  15 . An adjustment tab  17  is affixed to the plate so as to project upwardly and perpendicularly from the top face  77  of the plate. The bottom face of the plate (not illustrated) rests on flange  6 . The length of the plate as illustrated by dimension arrow  45  is shorter than the length of the corresponding dimension of border opening  14 . 
     Removable louver cradle assembly  5  is formed of plural channels  16  and parallel beams  19 . A web  39  resides in each channel so as to provide support for a piece of flooring, giving each channel an H-shape. Channels  16  rest on lips  21  of beams  19  and are positionally spaced and affixed to the beams by welding or any other suitable mechanical attachment method such that the longitudinal axis of adjacent channels  16  are parallel. The spacing of the channels  16  is such as to define equal louver spaces  18  between any two adjacent channels. The louver cradle rests on the top face of the plate. 
     The border support height as indicated by dimension arrow  40  is approximately equal to the depth defined between the top of H-shaped channel  16  and the floor of web  39  as indicated by dimension arrow  38 , allowing for the accommodation of identical thickness flooring materials in the border support and the louver cradle channels. The height of interior side walls  12  as indicated by dimension arrow  41  is approximately equal to the combined thickness of plate  13  and the height of beam  19  as indicated by dimension arrow  43 . This allows for the top surfaces of identical flooring material installed in the border support and the louver cradle channels to be flush when the louver cradle and air adjustment plate are installed in the border support. 
     FIG. 2, a perspective view of the preferred embodiment of the forced air vent register when assembled, shows air adjustment plate  13  and louver cradle  5  placed within opening  14  (FIG. 1) of border support  2 . Tab  17  fits between beam  19  and interior side wall  12 , thus projecting from the top face of the register. 
     Referring to FIG.  1  and FIG. 2 together, it can be seen that register  22  is assembled by stacking louver cradle  5  onto air adjustment plate  13  which in turn stacks on top of border support  2 . Bottom lips  21  defined on beams  19  of the louver cradle rest on the top face  77  of the air flow adjustment plate, while the bottom face of the air flow adjustment plate rests on flange  6  of the border support. In this configuration the top surfaces of louver cradle  5  are suitably maintained flush with the top surfaces of border support  2 . Note that the flanges  6  do not need to be provided on all four of the interior sides of the border support, and are only necessary on any pair of opposite interior sides. The preferred sides for the flanges are the interior sides parallel with the beams. The length of air flow adjustment plate  45  is less than the corresponding dimension of border opening  14  thereby allowing limited sliding movement of plate  13  along the direction of the longitudinal axis of the register. Slit openings  15  approximate the size of louver spaces  18  wherein both are slightly smaller than the H-shaped channel thickness  47 . Applying pressure on tab  17  in the direction of the longitudinal axis of plate  13  moves the plate within border opening  14 . This movement adjustably positions the slits anywhere between complete vertical alignment below the louver spaces and complete vertical alignment below the H-shaped channels, allowing for 0 to 100% adjustment of the air flow through the register. 
     FIG. 3, an enlarged cross sectional view of the preferred embodiment of the forced air vent register taken through line  3 — 3  of FIG. 2, illustrates the supporting relationship between the air adjustment plate  13  and lips  21  of beam. The location of channel web  39  is illustrated in phantom. Web top face  80  is approximately horizontally aligned with top face  82  of the border support bottom. 
     FIG. 4, an enlarged cross sectional view of the preferred embodiment of the forced air vent register taken through line  4 — 4  of FIG. 2, shows the spaced relationship between adjacent channels  16 . Louver spaces  18  are substantially equal between the channels. Note, that air adjustment plate  13  does not extend the entire distance between interior side walls  12 . 
     FIG. 5, a diagrammatic perspective view of a subfloor housing a forced air vent, illustrates a subfloor  24  with a cutout portion forming a vent opening  28  for the purpose of accommodating a forced air vent  26  to allow the flow of air between the air mover and the room. 
     FIG. 6, a diagrammatic perspective view of the border support of the preferred embodiment of the forced air vent register installed around a forced air vent opening, illustrates border support  2  affixed to subfloor  24  by nails or screws through beveled holes  7 . Border support  2  is manually positioned so as to allow vertical alignment between border opening  14  and vent opening  28 . Flange  6  of the border support has slightly smaller peripheral dimensions than the width and length of border opening  14  so that border support  2  actually protrudes minimally into the border opening. This ensures that the raw edges of the subfloor are concealed and that the register fits into the border opening with room for adjustment to obtain aesthetic alignment with the surrounding flooring. 
     FIG. 7, a perspective view of a tiled subfloor and border support, shows ceramic tiles  30  glued to subfloor  24  with grout  34  between adjacent tiles. Tile pieces  32  are affixed within channels  16  of border support  2 . Grout  34  fills the remaining space between tile pieces within border support  2  that reside perpendicular to each other  34 . 
     FIG. 8, an exploded view of a subfloor, a border support and a louver cradle, shows ceramic tile pieces  32  installed within H-shaped channels  16 . Plate  13  has been installed into border opening  14  and rests on flange  6 . 
     Referring to FIG. 9, an enlarged cross sectional view of the preferred embodiment of the forced air vent register, ceramic tile pieces  32  are affixed to border support bottom  8  and web  39  by a suitable adhesive  50 . 
     Referring to FIG. 10, a perspective view of a tiled floor with the preferred embodiment of the forced air vent register installed, illustrates louver cradle  5  positioned into the border opening  14  of border support  2 . Ceramic tile pieces  32  have been installed into channels  16  and into border support  2 . Tab  17  projects above and perpendicular to the surrounding floor. 
     The finished appearance of a preferred or alternate embodiment forced air vent register, is shown in FIG.  10 . 
     Referring to FIGS. 5-10, it can be seen that subfloor  24  has a cutout region forming vent opening  28  that is sized to accommodate forced air vent  26 . In use, border support  2  is affixed to subfloor  24  by nails or screws inserted through holes  7  or a suitable adhesive such that border support opening  14  is manually aligned with vent opening  28 . Note that it is not necessary for the border support to be affixed to the floor as its weight and the neighboring flooring will maintain its location. In this position flange  6  overhangs the edge of vent opening  28  and projects toward the center of vent opening  14 . The dimensions of border opening  14  are substantially similar to the dimensions of vent opening  28 , maximizing the air flow through register  22  and minimizing air resistance. 
     Once border support  2  is installed, pieces of tile  32  or flooring material are cut to fit into border support  2  and are adhesively affixed to border support bottom  8  with suitable adhesive  50 . The placement of the tile pieces within border support  2  may incorporate spaces between adjacent tiles for grout depending upon the size of the tiles used, the size of the register and the pattern of the tile installation. Typically the process of installing tiles  30  onto subfloor  24  will also be performed at this time. Similarly, pieces of tile  32  or flooring material are cut to fit into the grooves formed by each H-shaped channel  16  of louver cradle  5  and are adhesively affixed to channel webs  39  as shown in FIG.  9 . 
     Referring to FIG. 11, a perspective view of an alternate embodiment of the forced air vent register according to the present invention, shown disassembled, illustrates a different design for a louver cradle  5 ′ and border support  2 ′. Here the removable louver cradle  5 ′ is formed of plural U-shaped channels  60  held equidistantly apart by channel supports  62  such that the longitudinal axis of adjacent channels are parallel. Adjacent to each channel are identical louver spaces  64 . Channels  60  have notches  66  at either end that protrude beyond channel bottoms  68 . Border support  2 ′ is approximately identical to border support  2  except interior side wall  12  of border support  2  is deeper than interior side  72  of border support  2 ′ because the depth of H-shaped channel  16  is approximately twice the depth of U-shaped channel  60 . Thus cradle flange  6 ′, bottom  8 ′, exterior side walls  10 ′ and interior border opening  14 ′ are identical to their counterparts cradle flange  6 , bottom  8 , exterior side walls  10  and interior border opening  14 . This alternative embodiment does not employ an air adjustment plate, although one can be provided, if desired, in a manner corresponding to that of the preferred embodiment. 
     Referring to FIG. 12, an enlarged cross sectional view of the assembled alternate embodiment of the forced air vent register taken in the direction of line A—A of FIG. 11, the notches  66  of U-shaped channels  60  rest on flange  6 ′ of border support  2 ′ thereby supporting the louver cradle  5 ′. Channel supports  62  are affixed to the bottom of channels  60  so as to reside perpendicular to the longitudinal axis of the channels and form the louver cradle  5 ′. 
     Referring to FIG. 13, an enlarged cross sectional view of the assembled alternate embodiment of the forced air vent register taken in the direction of line B—B of FIG. 11, the spaced relationship between adjacent channels  60  is illustrated. Louver spaces  64  are substantially equal between the channels  60 . 
     Referring to FIG. 14, an enlarged cross sectional view of the assembled alternate embodiment of the forced air vent register as in FIG. 13 with tile installed, the placement of tile pieces  32  within border  2 ′ and louver cradle  5 ′ may be observed. A suitable adhesive may be applied to border support bottom  8 ′ and channel bottom  68  to retain tile pieces  32  therein. 
     Referring to FIGS. 11-14 together, in the alternate embodiment louver cradle  5 ′ is fitted into opening  14 ′ by resting channel bottoms  68  upon cradle flange  6 ′. When louver cradle  5 ′ is installed into border support  2 ′, notches  66  protrude beyond flange  6 ′ to prevent any relative movement between the louver cradle  5 ′ and border support  2 ′. Channel height  72  and border support height  70  are substantially similar and approximate the height that the combined flooring and adhesive rise above the subfloor. This height will vary to permit the register to accommodate flooring of standard dimensions such as ⅜ inch, ½ inch, ¾ inch, etc. When installed, register  22  is flush with the top surface of the surrounding flooring so as to blend in aesthetically with the environment and prevent bumping by footwear, furniture, etc. Because louver cradle  5 ′ merely rests on flange  6 ′, louver cradle  5 ′ is easily removable from border support  2 ′ for cleaning or retrieval of objects. Since preferably, both border support  2 ′ and louver cradle  5 ′ are made of steel, aluminum, brass or other suitably rigid material, a considerable weight may be placed on louver cradle  5 ′ without fear of deformation or damage. 
     Numerous further alternate embodiments are also available. In one such alternate embodiment, the two separate pieces that make up the air vent register, the border support and the louver cradle, are joined together to form a single register unit, allowing for two types of installation. In the first type of installation, this single register unit is permanently affixed to subfloor  24  allowing grout  34  to be installed between the border support exterior side and the adjacent tiles  30 . In the second installation method, grout  34  is not allowed to adhere to the border support exterior side and the register unit is maintained in place by its own weight and is thus removable for access. 
     The dimensions of registers according to other alternate embodiments may vary. For example, channel heights  38  and  72  and border support height  40  may be substantially similar to each other but with a lesser dimension height than that of the flooring affixed to the subfloor surrounding register  22 . In this way, the only parts of the register visible are the cut tile pieces. Exterior side walls  10 , interior side walls  12  and channels  16  would he hidden from view in such an embodiment. 
     Preferably, the register according to the invention is used with ceramic tiled floors, but numerous other flooring materials work equally as well including wood, marble, granite, rubber, carpet, laminate flooring, linoleum, vinyl, for example. 
     While the preferred embodiment employs a louver cradle with parallel channels spaced equidistantly, other patterns are possible for aesthetic effect. Such patterns can employ different angles for the channels, different geometric shapes for the border support, varying channel thickness, or different louver spacing. The air adjustment plate is suitably profiled correspondingly. 
     Although the embodiments disclosed refer to a forced air vent register for flooring, this invention can also be used for wall or ceiling registers where wood, tile, sheetrock or plaster have been applied to the wall or ceiling. Due to the numerous shapes and sizes of forced air vents, the actual dimensions of these registers vary. 
     Accordingly, a forced air vent register is provided for that receives pieces of flooring such that, when installed, resides flush with the top surface of the surrounding floor thereby reducing the visual obtrusiveness of the grille and increasing the aesthetic appeal of the surrounding floor. A sliding adjustable air plate allows for the adjustment of the flow of air through the register. 
     While plural embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the invention in its broader aspects. The appended claims are therefore intended to cover all such changes and modifications as fall within the true spirit and scope of the invention.