Conveyor process for forming an insulated register box

A process for forming an insulated register box having a body and a duct in which an expandable polymeric material is introduced into the interior of the body. The body is placed onto a support, a plug is positioned into an interior of the body such that the expandable polymeric material expands between the back wall of the body and the plurality of side panels and the plug, positioning the assembly between a pair of conveyors such that the pair of conveyors holds the assembly tightly sandwiched therebetween, and conveying the assembly to another position adjacent an opposite end of the pair of conveyors.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to ductwork for heating, ventilation and air-conditioning (HVAC) systems. More particularly, the present invention relates to the processes for forming register boxes as used in such systems. More particularly, the present invention relates to conveyor-style processes for forming such register boxes.

To create the desired ambient conditions within a structure, a typical HVAC system is installed for circulating and/or conditioning air drawn from the interior of the structure and returned to the interior of the structure. A central unit or several units are located in or near the structure, each unit comprising a fan for air circulation and optionally comprising a heating, humidification, or cooling system for conditioning the air passing through the central unit.

To conduct air to and from each central unit, ducting is provided in the structure. The ducting includes supply-air ducts which provide conditioned air to the interior of the structure and are connected to the outlets of each central unit and return-air ducts which return air to each central unit and are connected to inlets of each central unit. Supply-air ducts typically terminate in supply-air register boxes mounted to the walls, the ceilings, or other surfaces within the interior, whereas return-air ducts typically begin at register boxes mounted to a surface within the interior, such as a wall, ceiling, or floor. There are usually many more register boxes for supplying air than for returning air, with those for returning air typically being substantially larger than those for supplying air.

To increase efficiency, building codes are being revised to require substantially airtight HVAC systems. In the past, a standard technique has been utilized for forming such sheet-metal register boxes. A form is cut from a rectangular, planar metal sheet. The form has cutouts for corners or other features to allow bending of the form into the desired shape. Cutouts define the height of the sides and an overlapping flap is formed by cutting a slot at each cut out. The sides are bent along bend lines to lie in intersecting planes so as to form an open-bottom, rectangular enclosure of a register box, with the vertical edges of the sides abutting the inside surfaces of the sides. The flap is folded around each corner that lies adjacent the outer surface of the side and then fastened to the side with rivets. In order to complete the register box, a circular duct connector or is connected to a circular cutout in the upper surface of the box. Prior art register boxes are also formed with abutting edges to form the enclosure. The abutting or overlapping edges may be fastened by adhering or by other fastening means, such as spot welding.

The method described above produces ducting enclosures that often leak conditioned air through the gaps between the edges at the corners, or, in the case of enclosures formed with multiple pieces, through the seams where the pieces are joined together. The prior-art method includes many labor-intensive steps to form the enclosures, including the cutting of the planar sheet and the fastening of the edges.

In order to achieve the requisite efficiency in compliance with building codes, insulation is used with such register boxes. The formation of the insulation of the register boxes has become somewhat of a problem. Since the boxes are conventionally made of sheet metal, such as galvanized steel or aluminum, the insulation must be applied to either or both the inside and outside of the register box either before or after it is installed. The cutting and fastening of the insulation to the box is tedious and time-consuming. As such, it is thereby rather expensive in terms of the cost of the insulation material and in terms of the amount of time required to properly insulate the register box.

The placement of insulation can be a time-consuming, hazardous, and tedious task. Typically, a large section of fibrous material requires a cutting into various shapes that fit within the interior of the register box. This fibrous material is then affixed to the walls on the inside of the register box by hand. Often, many steps are required so as to properly fit the insulation material within the register box. Furthermore, since fibrous material is being manually handled by workers, there can be exposure to airborne fibers. The cutting and fitting of the insulation material within the register box is extremely tedious and boring to workers.

In the past, various patents have issued relating to register boxes and to the insulating of such register boxes. For example, U.S. Pat. No. 3,985,158, issued on Oct. 12, 1976 to J. V. Felter, describes a box for mounting diffusers wherein the main body of the box is made of expanded plastic or similar material. One or more connection elements are molded within the walls of the box to provide for connection of the box to the building structure and to a duct and also to reinforce the box.

U.S. Pat. No. 4,735,235, issued on Apr. 5, 1988 to Anderson et al., discloses an insulated duct end system. The system includes duct assemblies and transition components for interconnecting the duct assemblies. Each duct assembly includes an insulated duct having a rigid sleeve within at least one end. Each sleeve includes an abutment ring and orifices in the ring for permitting air to flow into the insulated area to balloon the layer and improve its insulative effect.

U.S. Pat. No. 5,095,942, issued on Mar. 17, 1992 to G. C. Murphy, teaches a plastic self-insulating ductwork system. The system includes a distribution box which includes an upper portion having a plurality of walls and a bottom plate. The distribution box is joined to interconnecting duct lines by adapter conduits. The adapter conduits are adapted at one end for connection to an opening in the wall and are adapted at the other end for connection to an adjoining duct line. U.S. Pat. No. 5,219,403, issued on Jun. 15, 1993 the G. C. Murphy, discloses a similar type of self-insulating ductwork system as that of U.S. Pat. No. 5,095,942.

U.S. Pat. No. 5,658,196, issued on Aug. 19, 1997 to T. L. Swaim, provides an air duct diffuser for attachment to a ceiling grid. The diffuser includes a frame which mounts to the ceiling grid and a louver which mounts to the frame for directing diffused air within an associated airspace. A pre-formed composite housing of insulating material mounts to the frame and has punch-out duct openings of varying sizes.

U.S. Pat. No. 5,749,190, issued on May 12, 1998 to S. R. Williams, shows an HVAC register box having no welded or riveted corners and also a process for making such an HVAC register box. The register box is fabricated from a single sheet of material without cutting. The register box has superior rigidity and resistance to air leakage at the joints or corners.

U.S. Pat. No. 5,957,506, issued on Sep. 28, 1999 to M. D. Stepp, provides a sheet-metal insulated register box. The register box has an adjustable elbow fitting that is coupled directly to an air inlet panel of an air distribution register box by having roll-formed flange portions that are mated in interlocking, overlapping engagement with each other. The air inlet panel includes an outwardly flared coupling flange bordering an air inlet opening. The neck of the sheet-metal elbow includes a folded coupling flange that is dimensioned for interfitting, overlapping engagement with the outwardly-flared elbow coupling flange.

U.S. Patent Publication No. 2008/0014860, published on Jan. 17, 2008 to Heitman et al., discloses a method and apparatus for eliminating register boxes. A collar plate assembly interfaces with metal air ducts and is provided with at least one spring indentation ring to accept two or more locking springs. The locking springs are used to attach the ceiling register to the collar plate assembly. The collar plate assembly uses mounting rails that attach the assembly to either the ceiling or wall supports. A trim ring is inserted in the cutout that attaches between the collar in the ceiling so as to eliminate air leakage and so as to provide an essentially smooth flow of air from the supply duct to the inside of the structure.

U.S. Patent Publication No. 2004/0130154, published on Jul. 8, 2004 to Stepp et al., shows a substantially airtight register box for HVAC systems. The register box has a body formed from at least one planar sheet. The body has an inlet and outlet. At least one of the inlet and the outlet is formed by folding corners of the planar sheet to form planar sides that lie in intersecting planes. The enclosure is then mounted to a surface of an interior area of a structure and is connected to ducts for communicating air between the interior area at a central air-handler unit.

U.S. Patent Publication No. 2008/0045137, published on Feb. 21, 2008 F. Rosal, discloses an insulated plenum box for heating, ventilating and air conditioning duct systems. This plenum box has insulation sprayed onto either the inside or outside of the plenum box in order to match the R-value of the connecting insulated duct.

The present Applicant is the owner of several patents and patent application publications related to such register boxes and the processes for forming such register boxes. For example, U.S. Patent Application No. 2018/036,3942, published on Dec. 20, 2018 to the present Applicant, describes an insulated register box and process for forming the insulated register box. This register box has a body with a plurality of side walls arranged in a generally rectangular or square configuration and a plurality of flanges extending inwardly from the plurality of side walls. An expandable polymeric material is affixed to an inner side of each of the plurality of side wall such that the expandable polymeric material has a portion extending across one end of the body inwardly of the plurality of flanges. A sheet is positioned over the portion of the expandable polymeric material at one end of the body such that the sheet is interposed between the plurality of flanges and the portion of the expandable polymeric material. The expandable polymeric material and the sheet are cuttable so as to open to the interior of the register box.

U.S. Pat. No. 10,648,695, issued on May 12, 2020 to the present Applicant, describes a register box with a boot rail adapter that has an insulating material affixed within the register box, a guide rail affixed to a side panel of the register box, and a rail having a section received in a slot of the rail guide. The rail is adapted to be affixed to a supporting surface, such as a joist. The rail guide is slidable relative to the rail. The rail guide is affixed to an exterior surface of the side panel.

U.S. Pat. No. 10,309,682, issued on Jun. 4, 2019 to the present Applicant, teaches a process for insulating a register box in which the register box has a plurality of side panels arranged in a generally rectangular configuration and a duct opening through a wall that extends across the generally rectangular configuration. This process involves flowing an expandable polymeric material toward the plurality of side panels, placing the register box into or onto a support structure, introducing a liner over the flowed expandable polymeric material within the register box, and placing a form onto the liner in the register box so as to shape the expandable polymeric material within the register box. The form and the liner then removed from the register box.

U.S. Patent Application Publication No. 2018/0320921, published on Nov. 8, 2018 to the present Applicant, teaches an insulated register box apparatus with a boot rail adapter which has an insulating material affixed within the register box, a rail affixed to a side panel of the register box, and a rail guide having a slot that receives a section of the rail therein. The rail guide is adapted to be affixed to a supporting surface. The rail is affixed at least one of the side panels of the register box. The rail is slidable relative to the rail guide. The register box has a plurality of side panels and a duct that opens to an interior of the plurality of side panels. The insulating material extends inwardly of the plurality of side panels.

U.S. Patent Application Publication No. 2018/0187919, published on Jul. 5, 2018 to the present Applicant, teaches an insulated register box for HVAC installations that has a body with a plurality of side panels arranged in a generally rectangular or square configuration and a wall extending across the rectangular configuration. A duct opens through the wall so as to communicate with an interior of the body. An expandable foamed polymeric material is affixed to an inner side of the side panels. The wall has a surface extending from the opening of the duct to the side panels. The expandable foamed polymeric material is affixed to the surface of the wall.

U.S. Pat. No. 9,951,969, issued on Apr. 24, 2018 to the present Applicant, describes an insulated register box and a method for forming such an insulated register box. The register box has a body with a plurality of side panels arranged in a generally rectangular or square configuration and a wall extending across the rectangular configuration. A duct opens through the wall so as to communicate with the interior of the body. An expandable foamed polymeric material is affixed to an inner side of the side panels. The wall has a surface extending from the opening of the duct to the side panels. The expandable foamed polymeric material is affixed to the surface of the wall.

With these prior patents and patent application publications, the process for forming the register box involved the use of a carousel-type of operation. In essence, the worker would place the assembly into a “Lazy Susan” type of carousel and rotate the carousel as the expandable polymeric material would dry or cure during the rotation of the carousel. This operation was excellent in practice, but the Applicant in these prior patents and patent application publications found that it was not well suited to high production volumes. It was also very labor-intensive. This operation involved a lot of manual manipulation that could result in potential injury to workers. Ultimately, a great deal of lifting was required in order to place plates, plugs and supports within each of the openings of the carousel. As a result, production was slow. The production of such register boxes was very much limited due to the efficiency of the particular worker at the carousel. These carousels also occupied a relatively large footprint within the factory. It was not adapted to efficiently allow for multiple carousels to be employed within the factory environment. If multiple carousels were employed, the workers associated with such carousels were significantly spaced from one another. As such, the use of a common foam gun or other appliances was somewhat limited. As such, a need developed so as to enhance the ability to produce large volumes of such insulated register boxes while reducing labor efforts required for such production.

It is an object of the present invention to provide a process for forming an insulated register box which allows the register boxes to be produced at a relatively high rate.

It is another object of the present invention to provide a process for forming an insulated register box which allows multiple systems to be in employed in a side-by-side relationship.

It is another object of the present invention to provide a process for forming an insulated register box that reduces the amount of labor required for the production of such insulated register boxes.

It is another object of the present invention to provide a process for forming an insulated register box which reduces the amount of effort by the worker in the production of such an insulated register box.

It is a further object of the present invention to provide a process for forming an insulated register box which allows the workers to work side-by-side within a relatively small footprint.

It is still a further object of the present invention to provide a process for forming an insulated register box which reduces the costs required in the production of such register boxes and reduces the amount of labor required for such production.

BRIEF SUMMARY OF THE INVENTION

The present invention is a process for forming an insulated register box in which the insulated register box has a body with a plurality of side panels and a back wall and has a duct extending through an opening in the back wall. The process includes the steps of: (1) introduce an expandable polymeric material into an interior of the body; (2) placing the body onto a support; (3) positioning a plug into the interior of the body such that the expandable polymeric material expands between the back wall and plurality of side panels and the plug; (4) positioning the plug, the body and the support between a pair of conveyors adjacent one end of the pair of conveyors such that the pair of conveyors holds the body and the duct and the expandable polymeric material tightly sandwich therebetween; (5) conveying the body, the duct, the expandable polymeric material and the support to another position adjacent an opposite end of the pair of conveyors; (6) removing the support, the duct, the body, the expandable polymeric material, and the plug from the pair of conveyors; and (7) separating the plug from the body and the expandable polymeric material.

The duct is welded to the back wall of the body such that the duct has a portion extending into the interior of the body. The step of introducing the expandable polymeric material includes introducing the expandable polymeric material into the interior of the body in a location between the portion of the duct at least one of the plurality of side panels. The step of introducing the expandable polymeric material further includes spraying the expandable polymeric material from a foam gun to the interior of the body. The foam gun is connected to a supply of the expandable polymeric material.

The support is a block having a hole formed at a top side thereof. The step of placing the body onto the support includes inserting the duct into the hole of the block. The back wall of the body resides on the top surface of the block.

A plastic sheet is positioned over the end of the body opposite the back wall. This plastic sheet will be interposed between the plug and the expandable polymeric material. In other words, when the plug is inserted into the interior of the body, the plastic material will wrap around the plug so as to be interposed between the exterior of the plug and the expandable polymeric material. The step of separating includes lifting the plastic sheet from the expandable polymeric material so as to define a cavity on the interior of the body. The cavity communicates with the interior of the duct.

After the plug is removed, the plug is placed on a top of one of the pair of conveyors such that the plug returns to the original end of the pair of conveyors. Also, the support can be placed onto the top of the uppermost conveyor of the pair of conveyors so that the support also returns to the original end of the pair of conveyors. Since the portion of such conveyor holding the insulated register box assembly thereagainst moves in one direction, inherently, the return direction will be at the top of such conveyor so as to allow these items to be returned to the worker at the origin or beginning of the pair of conveyors. The expandable polymeric material will cure as the support, the duct of the body move along the pair of conveyors to the opposite end of the pair of conveyors.

The duct, the body and the expandable polymeric material placed onto a cleaning conveyor so as to clean the expandable polymeric material appearing on an exterior of the duct. This cleaning conveyor has a plurality of brushes supported thereon or adjacent thereto. The step of placing the duct further comprises placing the body onto the cleaning conveyor such that the duct extends upwardly and moves with the cleaning conveyor such that the duct and the body pass between the plurality of brushes. Each of the pair of conveyors will move in an identical speed. One pair of the plurality of brushes will clean the exterior surface of the duct. Another pair of the plurality of brushes will clean the exterior of the body of the duct.

In the present invention, the original steps 1-7 are repeated for another duct and body. Importantly, the repeated steps are staggered from original steps such that the ducts and bodies of this repeated step are staggered or offset from the ducts and bodies of the original process.

The duct is welded to the back wall of the body so as to fix a position of the duct in the back wall. The assembly of the body and the duct is lifted from of a pallet adjacent to one end of the pair of conveyors prior to introducing the expandable polymeric material. The plug is positioned against an end of the duct interior of the body. The duct and the body and the expandable polymeric material are removed from an end of the cleaning conveyor. The plurality of brushes are supported in a position in spaced relation to the top of the cleaning conveyor.

The step of conveying includes compressing an upper end of the plug and against the end of the body opposite the back wall so as to retain the expandable polymeric material within the interior of the body. The plug bears against the end of the duct so as to prevent the expandable polymeric material from entering the interior of the duct upon expansion.

In the present invention, the pair of conveyors are maintained within a housing. Forced air is extracted from the interior of the housing so as to remove any vapors that may occur within the housing. In particular, the housing includes a pair of openings directed to the uppermost conveyor. A vacuum is applied so as to draw any fumes or air from the surfaces of the upper conveyor. This facilitates curing or drying of the expandable polymeric material. Another portion of the housing is placed below the lowermost conveyor. Another vacuum is applied to the interior of this portion of the housing so as to remove any vapors that may appear on the lowermost conveyor.

A scraper is positioned adjacent to an end of each of the pair of conveyors. The scraper is removes any debris or foam that might reside on the lower surface of the uppermost conveyor or on the upper surface of the uppermost conveyor. The scraper will discharge unwanted materials downwardly into a collector or receptacle. The collector or receptacle can then auger-feed the foam and debris to a remote location.

This foregoing Section is intended to describe, with particularity, the preferred embodiments of the present invention. It is understood that modifications to these preferred embodiments can be made within the scope of the present claims. As such, this Section should not to be construed, in any way, as limiting of the broad scope of the present invention. The present invention should only be limited by the following claims and their legal equivalents.

DETAILED DESCRIPTION OF THE INVENTION

Referring toFIG.1, there shown the insulated register box10as formed in accordance with the process of the present invention. The register box10includes a body12having side panels14,16,18and20formed into a generally rectangular configuration. A back wall22extends across this generally rectangular configuration. A duct24is illustrated as affixed to the wall22so as to open to the interior of the body12. The duct24includes an open end26so as to allow duct24to be connected to the HVAC system of a building. Conventionally, the register box10will be formed and pieced together through the use of tack welding. Tack welding is a very efficient manner of forming the register box. In particular, the duct24can be tack welded to the body22. As such, the duct24will have a portion that extends into the interior of the body12defined by the side panels14,16,18and20.

FIG.2shows a side view of the register box10. As can be seen inFIG.2, the side panel14is particularly illustrated. The duct24is illustrated as affixed to an and extending outwardly of the back wall22. It can be seen that there is a lip44that extends outwardly of the end46of the body12. The lip44, as will be described hereinafter, extends outwardly of a flange48. Flange48extends inwardly from the side panels14,16,18and20such that the inner edge as defined in aperture50opens to the interior of the body12.

FIG.3is an end view of the register box of the present invention. InFIG.3, it can be seen that the duct24is affixed to the back wall22. Back wall22includes a surface52that extends from the opening of the duct24to the side panels14,16,18and20of the body12. The expandable polymeric material60resides over the surface52and extends to the side panels14,16,18and20. As such, the expandable polymeric material60effectively insulates the back wall22in the area adjacent to the opening of the duct24.

FIG.3further shows the nature of the flanges48. Flanges48has a particular width. In accordance with the present invention, the expandable polymeric materials60will reside against the side panels14,16,18and20and have a thickness approximately equal to the width of the flanges48. The lip50is illustrated as extending in transverse relationship from the flange48.

FIG.4is a cross-sectional view of the register box10of the present invention. As can be seen inFIG.4, the expandable polymeric material60is illustrated as positioned against the side panels14and18. A similar configuration will occur with respect to the side panels16and20. The expandable polymeric material60is illustrated as having a thickness approximately equal to the width dimension of the flange48. The flange48, along with the lip50, defines an aperture64that opens to the interior of the body12. The expandable polymeric material60also has a portion that resides against the inner surface of the wall22. This portion60extends from the side panels14and18so as to bear against the portion61of the duct24that extends into the interior of the body12.

In this configuration, the expandable polymeric material60can serve as insulation. This insulation is compliant with national building codes, is fire resistant, and also avoids the use of fibrous insulation material. As such, this type of material, since it avoids the fibrous material in the assembly requirements, improves the health and safety of workers that assemble the register box10. The insulation created by the expandable polymeric material60does not require any alterations in the structure of the body12or of the duct24. The insulation material causes the register box10to be very energy-efficient.

InFIG.4, it can be seen that there is no expandable polymeric material located on the inner wall68of the duct24. If any expandable polymeric material would enter the duct24or reside on the inner wall68of the duct24, and it could hamper air circulation. As such, it was felt that it was important to block any movement of the expandable polymeric material from entering the area of the interior of the duct24. Since the expandable polymeric material60extends to the aperture that is defined by the lips50and the flanges48, it does not interfere with air flow into the interior of the register box. The movement of the expandable polymeric material toward the interior of the duct24is blocked by the portion61of the duct24. The blocking of the expansion of the expandable polymeric material into the interior of the duct will be further blocked by the process of the present invention, to be described hereinafter. As such, the present invention remains substantially aerodynamic while, at the same time, improving the insulating qualities required of the register box10.

FIG.5shows an initial step in the process of the present invention. InFIG.5, it can be seen that there is a supply of expandable polymeric material70that is connected by a conduit72to a foam gun74. A pump can be used in association with the conduit72and/or the supply70in order to allow the gun74to spray the expandable polymeric material76into the body12of the register box. In particular, it can be seen that the expandable polymeric material76is generally introduced into a corner80between one of the side panels14,16,18and20and the back wall22. The portion61of the duct24extends into the interior78of the body12so as to resist the flow of expandable polymeric material into the interior of the duct24. The small amount of expandable polymeric material that is placed into the interior78of the body12will suitably expand so as to cover the necessary area in order to create the insulation shown inFIG.4.

FIG.6shows an exploded view showing an assembly82of the various components to be introduced into the conveyor system of the present invention. The assembly82includes the register box10having the duct24extending outwardly of the body12. The duct24has portion61extending into the interior of the body12. A support84is shown below the register box10. The support84can be a metallic or wooden block that has a hole86formed therein. Hole86is sized and shaped so as to receive the duct24therein. The back wall22of the register box10will reside on the top side88of the support84. As such, this provides a strong and steady support for the register box10during the processes of the present invention.

FIG.6shows that the interior78of the register box faces upwardly toward an end90opposite to the back wall22. In order to form the insulation60, initially, a plastic sheet92will be placed over the upper end90of the body12. A plug94will then be inserted into the interior78of the body12. After the plug94is inserted into the body12, the plastic sheet92will envelop the exterior surface of the plug94so as to be interposed between the expandable polymeric material60and the exterior surface of the plug94. In essence, this plastic sheet92provides a barrier so as to allow the plug94and sheet92to be easily removed after the expandable polymeric material60has cured.FIG.6further shows that the plug has a lip or ledge96that extends outwardly from the remainder of the body. This lip or ledge96will be placed over the upper end of the body and over that portion of the plastic sheet92that extends outwardly over this upper end90of the body12so as retain the plastic sheet92in position. Ultimately, this will create a sandwiched configuration which will allow the system of the present invention to allow the insulated register box to be properly formed.

The plug94has a gasket seal affixed to the bottom thereof. The gasket seal can be formed of a polymeric or elastomeric material. The gasket seal can be affixed to the bottom of the plug94by adhesives or by a variety of other means. The gasket seal will sealingly engage with the end of the portion61of duct24within the interior78of the register box10. This tight sealing relationship will prevent the expandable polymeric material60from entering the interior of the duct24. Since the plastic sheet92will be interposed between the gasket seal and the end of the portion61of duct24, there will be no difficulty in separating the gasket seal from the duct24upon completion of the process.

The prevention of the expandable polymeric material from entering the interior of the duct24achieves a variety of advantages. Fundamentally, this presents a favorable and improved aesthetic appearance of the register box10. The absence of expandable polymeric material from the interior of the duct24will improve the aerodynamic characteristics of the duct24. The prevention of expandable polymeric material from entering the interior of the duct24reduces time and labor requirements associated with cleaning the interior of the duct upon completion of the register box10. It also serves to reduce material consumption and provide a more uniform use of the expandable polymeric material. As such, greater uniformity of the creation of the expandable polymeric material60is achieved. Since the gasket seal serves to prevent intrusion of the expandable polymeric material60into the interior of the duct24, there is no material loss into the interior of the duct24. As such, the amount of expandable polymeric material introduced by the foam gun74can be uniform throughout the production process.

FIG.7shows an end view of the plug94. It can be seen that the plug94has a generally tapered outer surface95. This tapered outer surface95will taper so as to narrow in diameter toward the bottom97. Lip96is at the wide end of the tapered exterior surface95of the plug94. The underside99of the lip96will bear against the plastic sheet92during the formation of the insulated register box10of the present invention. It can be can be seen that the gasket seal is affixed to the bottom97of the plug94. The gasket seal extends entirely across the bottom97of the plug94. As such, this provides a surface that can bear against the end of the duct within the interior of the register box10.

FIG.8is a perspective view showing the interior of the plug94. As can be seen, plug94can be formed of an aluminum or steel material. The exterior surface95is illustrated as tapering downwardly toward the bottom97. The interior101is hollow. Strut103extends across the hollow interior101. Strut103enhances the structural integrity of the plug94and enhances the ability to manipulate the plug during installation and removal. The lip96extends outwardly around the perimeter of the plug94at the upper end of the plug94. The strut103also facilitates the ability to remove the plug94from the assembled configuration once the insulating material is properly formed within the insulated register box10. The gasket seal is extending across the length and the width of the plug94. The gasket seal is affixed against the bottom97of the plug94.

FIG.9shows the assembly82residing at an end100of a lower conveyor102. As can be seen, the duct24is received in the hole86of the support84. The plug94has been received in the interior78of the body12. The plastic sheet92surrounds the exterior of the plug94and is interposed between the expandable polymeric material60and the exterior of the plug94. The conveyor102, as shown inFIG.9, will cause the relatively rigid belt104thereon to move in a generally clockwise manner. As such, the assembly82will move from the position at the end100of the conveyor102to a position located between conveyor102and conveyor106. Conveyor102has a length slightly longer than the length of the conveyor106so as to allow the placement of the plug94onto the assembly92. Ultimately, the assembly82will enter the area between the conveyors102and106. The rigid nature of the belt104of conveyor102and belt108of conveyor106will cause the plug94to compress against the end of portion61of the duct24and against the end90of the body12. This compression will allow the expandable polymeric material60expand and cure. The tight relationship between the plug94and the end of the portion61of the duct24will prevent the expandable polymeric material60from entering the interior of the duct24. This avoids those circumstances where the worker places the plug94too loosely onto the assembly such that expandable polymeric material leaks into the interior of the duct. Similarly, the tight relationship between the belt108and the plug94will cause plug94to always bear with constant force against the end90of the body12so as to prevent the expandable polymeric material60from escaping into the interior78of the body12.

As can be seen inFIG.9, the assembly82will continue to move along the conveyors102and106in a tightly compressed configuration. Ultimately, within the design of the present invention, the length of the conveyors102and106is configured so as to allow for a proper amount of curing time. In actuality, workers will continue to place separate assemblies82one after the other upon the conveyor102so that the process is a continuous process. The assemblies82will be spaced from one another throughout their travel with the conveyors102and106. The arrow110illustrates the direction of movement of the assemblies82on the parallel conveyors.

It is important to note that the unique feature the present invention is that the belt108of conveyor106moves in a counter-clockwise direction. As such, when the assembly82reaches the end of travel between the conveyors102and106, the assembly can be removed. As such, materials can be returned back to the end100for use by the worker. As can be seen inFIG.9, when the assembly82reaches the end of travel, the plug94is removed from the interior of the body12. This can be placed on the top of the belt108and returned back to the beginning of the conveyor. Similarly, the support84can also be placed on the belt108and returned back to the original position. As such, as the insulated register box is delivered to the opposite end112of the conveyors102and106, the return action of the conveyor106will allow each of these components to be returned back to their original position without the need for stacking and transport. As a result, the insulated register box can be created in a simple and efficient manner. This minimizes the number of workers required for the production of such register boxes and also simplifies the labor requirements for such assembly.

In the process of the present invention, fumes are produced during the formation of the register boxes. As such, a housing113is positioned over the conveyors102and106. There is an upper portion115of the housing113that has openings117and119opening to the interior of portion115. A pipe121is connected to the openings117and119. Ultimately, a vacuum is applied to the interior of the pipe121so as to create a section on the interior of the portion115of housing113. As such, gases will escape from the interior of portion115by virtue of this vacuum suction. Similarly, another portion123of the housing113underlies the conveyor104. Openings125and127serve to open to the interior of portion123. Openings125and127are connected to the pipe129. Once again, a suction is applied to the pipe129so as to draw any vapors from the interior of the portion123of housing113. The suction facilitates drying and curing of the expandable polymeric material. This action is shown by the arrows in fit inFIG.9.

On occasion, foam and debris131may form on the lower surface of the conveyor106. To remove this foam and debris131, a scraper133is affixed to the housing113at the end of the conveyor106. Scraper133will separate the foam and debris131such that the foam and debris can fall downwardly and be received within a receptacle135therebelow. Receptacle135can contain an auger conveyor137so as to transport the separated foam and debris to a remote location. Similarly, conveyor104also can have debris131on the upper surface thereof. Another scraper139is affixed to the housing113that adjacent to the end of the conveyor104. Scraper139will once again separate the foam and debris131from the conveyor104such that the foam and debris131falls downwardly into the receptacle139. This foam and debris is then transported to into the receptacle135and then transported by the auger conveyor137to a remote location.

FIG.10shows a plan view of a conveyor124of the assembly of register boxes of the present invention. As can be seen inFIG.10, the various register boxes122are arranged in spaced relationship upon the conveyor124. In actual operation, the register boxes122will be placed in staggered relation to register boxes126. As such, there are two rows in staggered relation that move from end128to an opposite end of the conveyor124. Each of the register boxes122and126is configured in the manner shown by the assembly82ofFIG.6. The staggering of the register boxes allows for ease of travel from end128to end130and such that the conveyor belts will can distribute an even and constant amount of pressure across the surfaces of the assemblies. Arrow132illustrates the direction of travel of these register boxes.

InFIG.10, it can be seen that there is a work pallet134and a foam gun136positioned adjacent to the end128of the conveyor124. As such, a worker can stand adjacent to the end128of the conveyor124and have an arrangement of the formed register boxes at one side on the work pallet134and the foam gun at the other side. Typically, the work pallet134will have a stack of the fabricated register boxes. The foam gun136allows the worker to begin the initial step of introducing the expandable polymeric material into the interior of the register box. As such, a single worker will have all of the tools necessary at his or her location adjacent to the end128of conveyor124so as to carry out the formation of the insulated register box of the present invention.

FIG.10shows that the ability to produce register boxes enhanced by the ability to have additional conveyors140,150and160in side-by-side relationship. As such, each of these conveyors124,140,150and160can be used for additional production of insulated register boxes. Under those circumstances where demand is great and greater production is required, all of the conveyors124,140,150and160can be used. Under reduced demand and lower production requirements, only one or a few of such conveyors need to be used. Each of the conveyors124,140,150and160will have an identical construction. As such, the workers will be adjacent to each other at the ends of the respective conveyors.

Each of the conveyors124,140,150and160will have their ends delivering product to transverse conveyor170. The transverse conveyor will deliver product from the end of conveyor124toward the cleaning conveyor180. Arrow182illustrates the direction of movement of the various insulated register boxes exiting the particular conveyors.FIG.10also shows the auger conveyor137. Auger conveyor137serves to receive the foam and debris131from each of the conveyors104and106. The auger conveyor137will also receive the foam and debris from the conveyors140,150and160. The auger conveyor137will then transport the foam and debris to a remote location141. A suitable siphon collector can be located at the remote location so as to suction the foam and debris from the surfaces of the auger conveyor137. As such, the conveyors will remain clean throughout their continuous use.

A worker will reside at end182of the conveyor180. As such, the arrangement and order of insulated register boxes being delivered to the transverse conveyor170is not important. Ultimately, these insulated register boxes will funnel in the direction toward the surface of the conveyor180. The worker at the end182will invert each of the register boxes so that the duct resides at the top of the insulated register box. It can then move along the cleaning conveyor180to brushes184. Brushes184are configured so as to clean the exterior surface of the duct. It was found that many customers preferred ducts that do not have expandable polymeric material on the exterior thereof. The appearance of such expandable polymeric material on the exterior of the duct can inhibit the ability to join the duct to the HVAC system. As such, this cleaning step is necessary so as to assure that the exterior surface of the duct is particularly clean. Ultimately, the cleaned insulated register boxes will exit the process of the present invention at the end186of the cleaning conveyor180.

FIG.11illustrates the configuration of the brushes used for the cleaning of the duct300of register box302. In particular, it can be seen that the cleaning brushes184are supported by frame186above the cleaning conveyor180. The cleaning brushes184can be suitably motorized so as to rotate for the proper cleaning of the duct300. Alternatively, the motion of the insulated register box302on the cleaning conveyor180can create enough motion out of stationary cleaning brushes184to effectively remove the expandable polymeric material from the exterior of the duct300. It can also be seen that there are also cleaning brushes185and187located on opposite sides of the body of the insulated register box302. As such, while the cleaning brushes184serve to clean the exterior surfaces of the duct300, cleaning brushes185and187serve to clean the exterior surfaces of the body of the insulated register box302. As such, the process of the present invention from provides a clean and debris free register box.

FIG.11also shows that there is a motor304associated with a shaft306that can drive the movement of the cleaning conveyor180. The shaft306and the motor304supported by structure308above an underlying surface310. Similar mechanisms can be used in association with the various conveyors described herein previously. The support of the cleaning brushes184to the side of and above the cleaning conveyor180avoids any interference with the proper motion of the cleaning conveyor180and avoids any interference with the movement of the body312of the insulated register box302.