Boot hanger mounting bracket

The present invention relates to duct systems, registers and ductwork components used with floor or ceiling registers employed in warm air heating, ventilating and air conditioning systems, and specifically to improvements for mounting and installing the components of the duct system, including register boots, mud rings and register grilles, in the walls, floors or ceilings of buildings.The invention includes an adjustable boot hanger mounting bracket assembly comprising a boot hanger frame portion and a support member portion; the ductwork components, which may include a pre-fabricated can-boot/mud ring assembly; a pair of boot hanger arms; and a register grille. The boot hanger mounting bracket assembly is formed of a sturdy yet bendable material so that it can be configured and adjusted on-site. Once configured, the boot hanger mounting bracket assembly is secured to the building structure by securing a pair of boot hanger arms to the ceiling joists, wall studs or other support structure. In this way, the boot hanger mounting bracket, through a direct attachment to the ceiling joist or wall stud, provides a positive inexpensive simple and error free way to mount the duct components.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to duct systems, registers and register boots, used as air ducts for warm air heating, ventilating and air conditioning systems, and specifically to improvements for mounting and installing the components of the duct system, including register boots, mud rings and air registers, in the walls, floors or ceilings of buildings.

2. Description of the Related Art

Forced air heating, cooling and ventilation systems, or “HVAC systems” are designed to provide control of space temperature, humidity, air contamination, differential pressurization, and air motion. These distribution systems use a network of ducts to deliver the heated and/or cooled air to the various rooms and spaces within a building structure. Of the many HVAC systems currently available, galvanized sheet steel duct systems are among the most widely used. These systems generally consist of an air heating and/or refrigeration unit, straight sections of duct, and multiple types of fabricated fittings and connections. From these fittings and connections, the straight sections of duct are connected to each other and to openings or vents in the rooms and spaces of the building structure. Currently, the ductwork connections and fittings are fabricated primarily by experienced sheet metal workers.

Where the ducts are accurately sized and the duct system is correctly designed, the air will be delivered to the rooms and spaces with a minimum of resistance. In HVAC systems, the ductwork interfaces with the room through one or more open-end duct portions. Generally, a grille or louver is mounted on the interfacing end of the duct to face into the room. Because the grilles generally must be mounted to the wall studs or ceiling joists, or to the ducts themselves, there is a risk that the grilles may be insecurely mounted or mounted at odd angles, particularly where the grilles are first attached and subsequently temporarily removed for wall painting or cleaning or other purposes.

Several considerations regarding the design of the connections and fittings used in HVAC systems are important. First, the connections and fittings are difficult to store, handle, and transport without incurring damage. In addition, due to their shape and design, they require a large quantity of space per unit to store and transport. These problems cause the production of excessive scrap and increased inventory holding and transportation costs for the distributor and customers.

Additionally, the configuration of the ductwork and grilles poses a problem for unskilled construction workers and is extremely time consuming. Generally, this work involves fitting together preformed components that frequently differ in dimensions and require careful measuring and positioning during the installation process so that the components fit together and so that no gaps are created. For example, a worker will commonly transpose the dimensions of the grille register onto the area of the wall or ceiling opening to ascertain the dimensions of the opening to be cut; or alternately he will select a standard size commercially available register grille to fit into a pre-existing opening. Because any measurements can introduce inaccuracies, the possibility that the components will not fit together or provide support for the grille register and boot in the wall or ceiling opening or create gaps between the edges of the opening and the grille register is a real concern. In these cases, another bracket must be brought to the site and used, or the grille opening must be modified or the grille register replaced with a different size so that the components fit together and so that the register and boot are securely supported in the opening in the wall or ceiling.

In light of the problems noted above and in an attempt to speed up the installation process and avoid waste of materials, new installation methods and devices have been sought. The present invention allows for easy transportation, storage and on-site installation while providing an adjustable assembly that provides solid backing for mounting the ductwork components.

SUMMARY OF THE INVENTION

It is an object of the present invention to overcome the above and other drawbacks by providing an assembly to support and mount ductwork components of heating, cooling and ventilation systems. The assembly has a simple and versatile construction and can be quickly and easily assembled. Further, the assembly may be stored and transported in a flattened state, and can be adjusted on-site to provide an accurate fit between the boot register, grille and wall, floor or ceiling opening, which reduces costs.

Generally, the invention includes a boot hanger mounting bracket assembly comprising an adjustable boot hanger frame portion and a support member portion; ductwork components such as a can-boot and mud ring that may be prefabricated; a pair of boot hanger arms; and an airflow control means, such as a register grille. The boot hanger mounting bracket assembly is configured so that the boot hanger frame portion preferably sits in a concentric fashion about the support member portion and comprises two pairs of parallel rearward projecting flanges along its sides. Alternately, the boot hanger mounting bracket assembly may be formed from a single piece of material or as a single unit, in which case the support member portion preferably is disposed along the inner perimeter of the boot hanger frame portion. A tabbed or lip portion of the support member portion is preferably configured at a right angle to the sidewalls of the support member so that the lip portion may lie flush against the rear surface of the boot hanger frame portion along its inner perimeter. The lip portion is preferably secured to the boot hanger frame portion by a securing material such as spot welds, button punches, epoxy or riveting. The boot hanger frame portion and support member portion are preferably configured so that a portion of the support member projects beyond the front face of the boot hanger frame to receive the airflow control means. The boot hanger frame portion is preferably formed from pairs of parallel strips so that it may be preformed or configured on-site by adjusting to the proper size and securing at the corners with a securing material, such as spot welds, button punches, epoxy or riveting. Likewise, the support member, or the entire device if formed as a single unit, may be preformed or may be transported in a flattened state to the site so that the boot hanger mounting bracket assembly can be configured on-site to interface with the particular ductwork components, such as can-boot, and register grilles. The support member portion may be formed of a sturdy yet bendable material so that it can folded on-site to form a pocket, into which the edge of the boot or other duct work component sits, and to form the lip portion, which is preferably secured to the boot hanger fame portion. The finished boot hanger mounting bracket assembly may then be secured to the building structure by securing the boot hanger arms to the boot hanger frame portion and to the ceiling joists, wall studs or other structure. In this way, the boot hanger mounting bracket assembly, through a direct attachment to the ceiling joist or wall stud, provides a positive inexpensive simple and error free way to mount the duct components.

OBJECTS OF THE INVENTION

It is an object of the present invention to provide a pre-assembled mounting bracket to support a register-grille and ductwork assembly.

It is a further object of the present invention to provide a pre-fabricated or pre-assembled can-boot and mud ring assembly to be used in commercial and residential HVAC applications.

It is another object of the present invention to provide an adjustable or “fit-to-size” mounting assembly for easy and accurate installation of ductwork components such as can-boots and register grilles.

It is yet another object of the present invention to provide a support and solid backing for mounting ductwork components such as can-boots and register grilles.

Another object of the invention is to provide a secure connection between building studding or ceiling joists and the mounting bracket, register and duct work components, such as can-boots.

A further object of this invention is to provide a mounting means that can be used when there are slight variations in the dimensions of the wall or ceiling opening or in the fit between the register grille and opening, and which does not require the use of spring-pressured mounting means or clips that must be affixed to the sheet rock or the like, so that the risk of deformation or damage of the ceiling or wall or ductwork is minimized.

It is a further object of the invention to provide an improved mounting bracket that may be formed from an inexpensive blank of foldable sheet material and may be effectively compressed together to form a compact bundle for shipment, transport to the installation site or for storage.

It is a further object of the invention to provide an improved mounting bracket having a sturdy connection to the building structure on which a register grille and ductwork components, such as a can-boot, is mounted and which provides minimum obstruction of the airflow through the associated ductwork.

It is a further object of the invention to produce a mounting bracket that allows adjustable installation and allows the register grille to be placed in close proximate fit to both the ductwork and the ceiling or wall in which the register grille is installed so that gaps may be minimized.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

The detailed description set forth below in connection with the appended drawings is intended as a description of presently-preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed and/or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments. However, it is to be understood that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.

Turning now toFIGS. 1to13of the drawings, and more particularly toFIG. 1, the typical environment which the present invention is operated is illustrated. As shown inFIG. 1, a typical vertical ceiling joist58is shown. AlthoughFIG. 1illustrates the present invention mounted in a ceiling, it is contemplated that the present invention may be mounted within the floor, wall or ceiling of a room. Attached to the ceiling joist58is a ceiling lid60formed from materials such as dry wall or sheet rock.FIG. 1also shows an airflow control means36, such as an air register grill or louver, mounted within the ceiling of a room.

The present invention generally comprises pre-fabricated ductwork components such as a can-boot2, mud ring7, a support member portion6, a boot hanger frame portion8, and a pair of boot hanger arms56. The present invention contemplates that the can-boot or other ductwork component2and mud ring7may be pre-fabricated and fit together prior to arriving at the work site, or alternately, semi-fabricated and configured at the site. An airflow control means36may be included and may comprise a commercially available standard register grille or grilles. The boot hanger arms56may be mounted to the ceiling joists58by fastening member such as nails or screws. It is contemplated that the invention will be disposed within an opening that is in communication with the ductwork of a central heating or cooling system or a ventilation system (not shown) of a structure and that the support member6defines an opening12asized to fit the airflow control means36. The support member portion6and the boot hanger frame portion8each have length, l dimension and width dimension, w, and when fitted together, define opening12b(FIG.2). Alternately, the support member portion6and the boot hanger frame portion8are formed from a single piece of material, or pre-formed as a single unit. The size of the opening12bmay vary to fit most residential and commercial HVAC needs and grille or register sizes. For example, in a first embodiment, the boot hanger frame portion8and support member portion6are configured to form a boot hanger mounting bracket assembly having an opening12bof approximately 31 cm in length by approximately 10 cm in width. Examples II, and III, herein illustrate without limitation other suitable dimensions.

Referring toFIGS. 2-5, the boot hanger frame portion8comprises a planar front surface14defining an opening and two pairs of parallel rearward projecting flanges16a,16b,18a,18balong, respectively its length, l, and width, w. Each flange comprises a pair of parallel edges34a,34band a rear edge36a. The flanges preferably serve to stabilize the position of the hanger arms56in relation to the boot hanger frame portion8and other components. The boot hanger frame portion8is preferably formed by two sets of parallel, galvanized metal strips26a,26band24a,24bforming respectively, the length, l, and width, w, of the boot hanger frame portion8. It is contemplated that the present invention may also be formed from a flat sheet of material by stamping and cutting. The strips or flat sheet may be formed from suitable materials comprising, for example, galvanized metals, aluminum, steel, high impact polystyrene or of resin formulations such as ABS resin.

Where the device is formed from a flat sheet of material, the flanges16a,16b,18a,18bmay be formed by manual bending of pre-etched lines90or by use of a suitable metal working devices. Preferably, flanges16a,16b,18a,18bare shorter in length than the respective parallel strips26a,26b,24aand24bfrom which they project rearward. For example, in the first embodiment, the width of the boot hanger frame portion8is formed from parallel strips24a,24b, having a finished size of approximately 2.5 cm wide and 15 cm long with reward projecting flanges16a,16bthat are approximately 12.5 cm long and 2.5 cm wide. In the first embodiment the length of the boot hanger frame portion8is formed from parallel strips26a,26b, that have a finished size of approximately 2.5 cm wide and 36 cm long and rearward projecting flanges18a,18bof approximately 33.0 cm long and 2.5 cm wide.

The boot hanger frame portion8may be formed by overlapping the parallel sets of metal strips26a,26band24a,24b, so that an overlap portion38is formed at the interface of perpendicularly positioned sets of strips24and26, which form the corners of the boot hanger frame portion8. For example, in the first embodiment, the overlap portion38forms a square of approximately 2.5 cm by 2.5 cm at each corner of the boot hanger frame portion8. Strips24a,24band26a,26bare preferably secured to each other via a securing material84, such as spot weld, button punches, rivets or epoxy, at the overlap portion38. The boot hanger frame portion8may be pre-formed or the securing step may be carried out on-site so that the boot hanger frame portion8can be adjusted and sized on-site. In the first embodiment, the secured parallel strips24a,24band26a,26bform a boot hanger frame portion8having an opening of approximately 10 cm wide by 35 cm long and having two pairs of rearward facing parallel flanges16a,16band18a,18bof, respectively, approximately 2.5 cm wide by 12.5 cm long and 2.5 cm wide by 33.0 cm long.

The support member portion6is configured to receive a portion of the can-boot, or other ductwork component,2and to interface with the boot hanger frame portion8. For example, in the first embodiment, the boot hanger support member portion6preferably has a finished length and width of, respectively; about 29.5 and about 9.5 cm to provide a good fit at the interface of the boot hanger frame portion8and the support member portion6. Example I summarizes the dimensions of a first embodiment of the boot hanger frame portion8and support member6. As shown in Examples II and III, however, the dimensions may vary according to the dimensions of the can-boot or other ductwork components2required and airflow control means36. The support member portion6may be pre-formed or taken to the site in a flattened state for easy transport. If formed on-site, the sides and dimensions of the support member portion6may be formed by manually bending the sheet material from which the support member portion6is formed. The material may comprise etched or marked lines90to facilitate the bending and formation process. For example, in the first embodiment, the finished support member portion6comprises two sets of parallel sides41a,41band40a,40bdefining a central opening12aand having an inner and an outer perimeter, and sidewalls defining a slot or “pocket”. The edges of the inner and outer perimeter of the support member portion6form, respectively, inner tabs42a,42b,42c42dand outer tabs48a,48b,48c,48d. To form the support member portion6from a flat sheet of material, a first step comprises folding inner perimeter tabs42a,42b,42cand42dtowards the central opening12aand folding outer tabs48a,48b,48c,48daway from the central opening12ato form two parallel sidewalls44a,44bdefining a pocket46(FIG.7). A second step comprises either forming the boot hanger frame portion8(where the device is formed as a single unit) or fitting the boot hanger frame portion8around the outer perimeter of the support member portion6and further bending the inner tabs42a,42b,42c,42dat approximate right angles to form a lip portion50on each side of the support member portion6(FIG.8). The boot hanger frame portion8is preferably disposed about the support member portion6such that the part of the inner42and outer tabs48forming the parallel sidewalls44a,44band pocket46project beyond the front surface of the boot hanger frame portion8(FIG.8). In the first embodiment, the, folded inner42and outer48tabs forming the parallel sidewalls44a,44band pocket46extend about 1.0 cm beyond the front face of the boot hanger frame portion8. The lip portion50is preferably configured so that it lies flush against the back surface of the boot hanger frame portion8from its inner perimeter. For example, in the first embodiment, an inner tab42of approximately 1.0 cm in width and outer tab48of approximately 2.0 to 2.5 cm wide are folded respectively towards and away from the inside of the central opening12ato form two parallel sidewalls44a,44bdefining a pocket46of approximately 0.1 to 0.25 cm in width. All but approximately 1.0 cm of the outer tab48is then further folded over at a right angle to form the lip portion50, which in the first embodiment is approximately 1.0 to 1.5 cm in width. In the first embodiment the bottom edges of the lip portion50along the length of the support member portion6are approximately 9.0 cm so that parallel side edges56a,56bmay be angled inward (similar to an envelope flap) to provide a good fit at the corners of the boot hanger frame portion8. The support member portion6can then be securely fastened to the boot hanger frame portion8by fastening the respective lip portion50to the surface of each of strips24a,24ban26a,26b. The front edges62of the can-boot or other ductwork component2may then be fit into the pocket46created by the folded inner42and outer tabs48before or after the lip portion50is formed. The material forming the support member portion6may then be pressed or otherwise adjusted to provide a snug fit between the support member portion6and can-boot or other ductwork component2. The adjustment step may be performed prior to securing the lip portion50to the boot hanger frame portion8and/or prior to securing the folded inner tab42to the interior surface64of the can-boot or other ductwork component2.

FIG. 1shows the configured boot hanger mounting assembly4attached to spaced apart ceiling joists58of a building structure by boot hanger arms56. The boot hanger arms56are attached to the ceiling joists58by a securing member66such as staples, screws or nails. The boot hanger arm56may be comprised of two identical linear elements68a,68band a mid-bracket70(FIGS. 9a,10b). The linear elements68a,68bhave a front surface72and lengthwise edges76a,76b(FIGS.9-10). Each linear element68may also comprise an outwardly projecting bump or ridge78running lengthwise along its front surface72(FIG. 10a). The two linear elements68a,68bpreferably interface with the mid-bracket70so that they are in sliding engagement with each other and with the mid-bracket70(FIG. 9a). The mid-bracket70preferably comprises a plurality of engaging means80such as tabs, hooks or grooves on its front and back surfaces (FIGS. 9b,10a). The plurality of engaging means80may be arranged in two parallel lines along the length of the mid-bracket70on its front and back94surface. The engaging means80preferably receive the edges of the linear element68while permitting it to move laterally in a sliding manner towards and away from the midpoint82of the mid-bracket70. The configuration of the linear elements68a,68band mid-bracket70permit adjustment of the boot hanger arm56to fit the particular dimensions of the ductwork and structure, such as the distance between ceiling joists58. Once adjusted, the configuration of the boot hanger arm56may be secured via a securing member96such as a screw and hole assembly that tightens to secure an edge of at least one of the linear elements68and prevents it from further sliding or movement (FIGS. 10a,10b). The boot hanger arm56may then be secured to parallel sides of the boot hanger frame portion8in order to secure the ductwork component2-boot hanger mounting bracket assembly4to the ceiling joists58or other part of the structure. For example, the boot hanger arms56may be fit beneath the lip portion50of the support member portion6and secured to the boot hanger frame portion8and support member portion6by a securing material84such as button punches, rivets, spot welds or epoxy. The linear elements68of each boot hanger arm56preferably comprise a hole86at their distal ends88(FIG. 9a) so that the boot hanger arm56may be secured to the ceiling joists58or other part of the structure by a securing member66, such as nails or screws.

Once the boot hanger mounting bracket4-ductwork component2assembly has been secured to the structure, an airflow control means36such as a grille louver or register may be fit to the opening defined by the configured boot hanger mounting bracket assembly4. The airflow control means36may then be attached to the ceiling lid60or other part of the structure by a securing member such as threaded screws. The airflow control means36will generally comprise sidewalls forming a passageway directing airflow from the duct through the register, as well as adjustable louvers for controlling the airflow. The louvers may be selectively rotatable by the user to control the direction and volume of airflow, including blocking the passageway. The perimeter of the air flow control means36preferably extend beyond the duct opening to abut against the ceiling lid60floor or wall on opposite sides of the duct opening to prevent gaps and to provide aesthetic appearance.

While the present invention has been described with regards to particular embodiments, it is recognized that additional variations of the present invention may be devised without departing from the inventive concepts. Additionally, the following Examples are presented to further illustrate preferred embodiments of the invention but are not intended to limit the present invention.

EXAMPLE IIDIMENSIONS OF SECOND EMBODIMENT OFSUPPORT MEMBER AND BOOT HANGER FRAME PORTIONFOR BOOT HANGER MOUNTING BRACKET ASSEMBLY(Configuration illustrated in FIGS. 13a-13g)DimensionApprox.(see FIG. 20)Measurement in cmd135.6d20.95d35.7, 10.2 or 15.2d420.3, 25.4 or 30.5d52.54d61.27d71.27d820.3

EXAMPLE IIIDIMENSIONS OF THIRD EMBODIMENT OF SUPPORTMEMBER AND BOOT HANGER FRAME PORTION FORBOOT HANGER MOUNTING BRACKET ASSEMBLY(Configuration illustrated in FIGS. 12a-12g)DimensionApprox.(see FIG. 21)Measurement in cmd925.4, 30.5 or 35.6d1033.6d111.27d121.27d132.54d143.81d1543.2d160.95d175.7, 10.2 or 15.2d1820.3