Abstract:
A connector frame for use as a support member for mounting grilles at ventilation openings in a building structure. The connector frame allows the grills to be mounted in slightly different locations to hide imperfections at the edges of the ventilation openings. The connector frame may include a pair of single connector frames that may be separated into two singly usable frames.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a continuation-in-part application of U.S. patent application Ser. No. 09/146,671 filed Sep. 3, 1998, now U.S. Pat. No. 6,192,680 the disclosures of which are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Technical Field 
     This invention relates to improvements in mounting grilles and louvers in the air duct outlets of heating and cooling systems in a building structure. Specifically, the invention relates to a frame positioned at the ventilation opening that allows a grill to be mounted to the frame. 
     2. Background Information 
     In forced air heating, cooling and ventilating systems, commonly referred to as HVAC systems, the rooms of the building structure usually have one or more open end duct portions of such systems entering into such rooms. It is normal practice to mount to the outlet ends of such ducts a grille or louver facing interiorly of the rooms. Such ends may be in single, double or multiple locations, spaced together or apart, for mounting the grilles in walls or ceiling for optimum distribution and/or collection of room air. The duct outlets are frequently located between wall studs or ceiling joists and their outlet grilles or louvers must be durably connected thereto preferably in air-tight replaceable arrangement. Air leakage around the grilles will result in inefficient air delivery and circulation as well as streaking or discoloration on adjacent walls or ceiling over time. Improper or insecure mounting of the grilles to wall studs or ceiling joists, or ducts per se, by juxtaposed mounting screws often requires the grilles to be attached to the studs or joists, or ducts, at odd angles in a non-uniform and insecure manner such as when the grilles are first attached and subsequently temporarily removed for wall painting or cleaning or other purposes. 
     Further, the outlet ends when open after duct installation and final construction of the building frequently allow dirt and building debris to enter the ducts which dirt and debris must be removed prior to temporary or final mounting of the grilles and operation of heating and cooling systems. Connection of the grilles to the metal duct ends, studs or joists poses a problem for unskilled construction workers and is very time consuming. It is very desirable to maintain cleanliness in the ducts during final construction to eliminate duct cleaning prior to overall building cleaning, dry walling, painting, wallpapering and operation of heating and/or cooling systems. Temporary installation of the grilles containing transparent plastic film or filters has been found to be highly desirable to maintain duct cleanliness both prior to and during initial operation of heating and cooling systems. The film and/or filters are usually removed prior to system operation. 
     SUMMARY OF THE INVENTION 
     The invention provides a connector frame that is positioned at the ventilation opening in a building structure. The connector frame carries a grill that covers the ventilation opening in an attractive manner. 
     The connector frame allows the grill to be attached to the frame in an adjustable manner so that wall covering imperfections can be selectively covered. The flanges of the connector frame define paired openings that allow the grill to be connected at different locations. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the accompanying drawings, the same reference numerals designate the same elements and component parts of the double and single connector frame in all views. 
     FIG. 1 is a front view of the improved rectangular double connector frame for connecting all ducts to grilles and louvers in a building structure indicating the medial line of severance for separating the double frame into two separate connectors. 
     FIG. 2 is an enlarged front view of a single smaller connector frame separated from the double frame of FIG.  1 . 
     FIG. 3 is a top elevational view of the smaller flanged connector frame shown in FIG.  2 . 
     FIG. 4 is an exploded view of the single smaller flanged connector frame shown in FIGS. 2 and 3 showing the attachment of the connector frame surrounding and connected to a duct outlet with a return-air grille ready to be attached thereto. 
     FIG. 5 is an enlarged vertical sectional view taken along the line A—A of FIG. 4 on a larger scale showing the duct outlet in a building wall, a flanged connector frame and grille mounted in place. 
     FIG. 6 is a view similar to FIG. 5 with a patented heat-resistant foil-faced duckboard material comprising the duct outlet material. 
     FIG. 7 is a vertical sectional view of the connector frame alone shown in FIGS. 5 and 6 having a filter member covering its open interior. 
     FIG. 8 is a view similar to FIG. 7 with a clear plastic film covering the interior open area of the connector frame. 
     FIG. 9 is an enlarged fragmentary perspective view of the apertured projections located medially along the short axis sides of the connector. 
     FIG. 10 is a front elevation view of an alternative embodiment of the connector frame of the invention. 
     FIG. 11 is a section view taken along line  11 — 11  of FIG.  10 . 
     FIG. 12 is section view of a small grill attached to the connector frame with the grill shifted to the right. 
     FIG. 13 is section view of a small grill attached to the connector frame with the grill shifted to the left. 
     FIG. 14 is section view of a large grill attached to the connector frame with the grill shifted to the right. 
     FIG. 15 is section view of a large grill attached to the connector frame with the grill shifted to the left. 
     FIG. 16 is a view similar to FIG. 10 showing an alternative embodiment of the invention used with larger ventilation openings. 
     FIG. 17 is a view similar to FIG. 16 showing an alternative embodiment of the invention for use with a single ventilation opening. 
    
    
     Similar numbers refer to similar elements throughout the specification. 
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1 of the drawings illustrates a double connector frame  10  which has a rectangular shape and a much longer length dimension than the shorter width dimension. One preferred size of the frame is about 32 by 7½ inches, although the size may be varied widely. The connector frame  10  has a planar surface  11  on one side and a pair of spaced-apart precisely-similar smaller flanged frames  12  and  13  on its other side. FIG. 1 shows the two equal smaller frames  12  and  13  within the single larger frame  10 . Both of the smaller frames  12  and  13  have open interior areas. 
     A medial line of severance  14  is shown in FIG. 1 centrally located between the two smaller frames  12  and  13 . The severance line  14  comprises a small lineal recess for separation of main frame  10  into single similar frames  12  and  13  by cutting or deep scoring. Thus, frame  10  can be severed along medial line  14  into two equally dimensioned smaller flanged frames  12  and  13 . Both smaller frames  12  and  13  have similar continuous peripheral flanges  15  and  16  extending around their perimeters with largely open areas there within. 
     Double frame  10  can be used to surround and be connected to a pair of side-by-side double duct outlets with no separation of its two smaller flanged frames  12  and  13 . By separating the main frame  10 , the two smaller frames may be used separately at spaced-apart locations to be mounted around two duct outlets. Main frame  10  has a uniform thickness of about {fraction (3/16)} inch and preferably is comprised of molded polymeric material such as poly-propylene. 
     The two smaller flanged frames  12  and  13 , when separated, are precisely-similar in size and dimensions, and each has the rectangular shape shown in enlarged FIG.  2 . The frame  12  is discussed here below, but the discussion also applies to the other frame  13  when separated. The rectangular flange  15  of frame  12  is located near its border  17  of nearly equal peripheral width. The open frame  12  has two intermediate members  18  and  19  which are extensions of its planar side, members  18  and  19  connecting the long axis sides of frame  12  for greater strength and stability. Integral members  18  and  19  of frame  12  extend through its open interior area. Members  18  and  19  have a similar thickness comparable to the border area  17  of the frame  12 . The continuous flange  15  of frame  12  has a thickness of about {fraction (3/16)} inch comparable to its border  17 . A series of small spaced-apart ribs  20  are formed on all sides of continuous flange  15  to strengthen the flange, the ribs facing outwardly at preferably equispaced locations on opposing sides of the flange. 
     A pair of outwardly-facing stepped projections  21  and  22  are formed medially on opposite short sides of frame  12  adjacent to and comprising a portion of flange  15 . The projections  21  and  22  are formed with each step having one of two small apertures  23  and  24  to receive mounting screws to hold grilles or louvers rigidly in place when attached thereto. FIG. 2 shows the two juxtaposed stepped projections  21  and  22  centrally on the short axis sides of the frame  12  in the corners between flange  15  and the border  17  with the two small open apertures  23  and  24  on each side, one aperture on each step. FIG. 3 shows in a top plan view the frame  12  and its continuous flange  15  with the spaced strengthening ribs  20  on its upper side. This view also shows the stepped character of projections  21  and  22  formed outwardly of flange  15 . The shorter step of projection  21  allows dry wall panels to be mounted against the higher step of the projection and its connector frame  12 . 
     FIG. 4 shows the subject connector frame  12  attached to spaced-apart studs  25  and  26  of a building structure. The short sides  27  and  28  of the frame border  17  are attached to the studs by stapling or nailing, for example, where the studs are normally comprised of wood. The flat face of frame  12  is directly attached to faces of parallel studs  25  and  26  and cross member  29  in the space therebetween. Cross member  29  is frequently mounted between the studs to form the duct opening  35  at the end of the duct. Dry wall members  30  and  31  are shown in FIG. 4 attached to the studs leaving the duct outlet  35  in open condition. A grille  32  is shown in FIG. 4 ready to be mounted on the connector frame  12  by a pair of threaded screws  33  and  34 . The screws are connected to the open apertures in the frame projections  21  and  22  after their passage through mounting holes  37  and  38  in the grille  32 . The dry wall panels  30  and  31  may be marked at locations of the lower projections for passage of screws through holes punched or drilled in the dry wall panel edges. The screws are preferably self-tapping for engagement in the opposing pair of apertures in projections  21  and  22  of the connector frame  12 , depending upon the grille size. 
     FIG. 5 shows in a vertical sectional view taken along line A—A of the connector frame  12  mounted on the perimeter of duct opening  35  in horizontal relation in a wall opening. The connector  12  may be similarly mounted on duct openings in ceilings as well as wall openings as desired or required. The grille  32  is directly attached to the connector frame  12  contacting the flanged edges of the frame  12 . 
     FIG. 6 is a view similar to FIG. 5 with the duct opening  35  formed of fireproof sheet duct material  36  sold under the name “Therm-O-Pan” as disclosed and claimed in U.S. Pat. No. 5,339,577 issued Aug. 23, 1994. The sheet duct material can be scored and bent into air ducts and stapled or nailed to the studs  25  and  26  to form the duct opening  35 . The connector frame  12  is similarly attached to the periphery of duct opening  35  and the grille  32  attached to frame  12 . Thus, the ducts can be formed of a wide variety of duct materials from sheet metal to essentially non-metallic sheet material. 
     FIG. 7 shows the frame  12  along with a continuous layer  37  of porous filtering material such as fiber glass covering the open interior area of the frame. The filter may be temporarily installed in the frame  12  for initial operation of the heating or cooling system of the building to prevent dust particles from entering the room for their collection and disposal. 
     FIG. 8 shows the frame  12  alone with a clear plastic film layer or sheet  38  covering the open area of the frame. The plastic film may be mounted on the flat surface  11  of the frame  12  for easy removal as desired. The transparent film sheet permits the construction workers to view the duct openings and prevent room dirt from room sources from entering the ducts during final construction. The filter or clear plastic materials are used as temporary measures to ensure duct cleanliness during latter stages of construction, such materials being mounted on frame  12  for their easy removal as desired before start-up of heating, cooling or ventilating systems. Clear or shaded or translucent plastic film, may be used on the connector frames and be peeled off prior to forced air passage. 
     FIG. 9 shows in an enlarged fragmentary view the projection  21  on frame  12  having the stepped contour with an aperture in each of the two steps. Aperture  40  is formed on the higher step and aperture  41  is formed on the lower step. Either of the pair of similar apertures on both sides of the frame may be used for grille attachment depending upon its standardized size. 
     The connector is normally mounted in level arrangement with a carpenter&#39;s level placed on its upper edge to mount the frame on the duct opening in a wall in horizontal relation. The border area  17  of the connector has a series of spaced markings molded into its sides to facilitate stapling or nailing of the connector to the wall studs. When the filter or transparent or translucent plastic film is utilized within the open area of the connector, such materials are quickly removed prior to operation of HVAC systems. The filter allows air to pass through but stops and collects dust and dirt from entering the room interior. The connector fits most commonly manufactured grilles and louvers having screw holes on their short sides in 30 by 6 and 14 by 6 inch sizes, for example. The connectors are made with safety edges and all sides and edges are so made for ease of handling and installation. 
     An alternative embodiment of the connector frame of the present invention is indicated generally by the numeral  100  in FIGS. 10-15. Connector frame  100  generally has a rectangular shape with a longer length dimension and a shorter width dimension. Connector frame  100  is configured to be broken into two independently-usable connector frames  102 . A scored severance line  104  is disposed in the body  106  of frame  100  to allow frames  102  to be separated. Line  104  may be defined in either the front or rear surface of body  106 . 
     At least a first flange  110  projects outwardly from body  106 . Flange  110  may be continuous as shown in the drawings or may include spaced sections disposed about the perimeter of the opening  112  of frame  100 . A second flange  114  extends outwardly from body  106  about opening  116  when body  106  is configured to form two frames  102 . Flanges  110  and  114  are aligned in along the horizontal dimension so that frame  100  may be used in a single large opening. 
     Body  106  includes wide side portions  120  that allow the size of flanges  110  and  114  to be adjusted for different width grills  32 . In FIG. 10, frame  100  includes broad side portions  120  so that flanges  110  and  114  are configured for smaller openings such as 12.5 inches with an combined width of 30.5 inches. In FIG. 16, an alternative frame  200  is depicted wherein flanges  110  and  114  are sized for grills  32  that are 14.5 inches wide with a combined width of 30.5 inches. In frame  200 , side portions  120  are smaller than in frame  100 . In FIG. 17, an alternative embodiment  300  is depicted that includes a single flange  302  sized to receive 24 inch grills. 
     In each of embodiments  100 ,  200 , and  300 , body  106  defines scored screw holes  150  that help the user to position screws and help the screws bite into body  106 . 
     In each of embodiments  100 ,  200 , and  300 , the flanges define opposed pairs of paired connector openings  160  having openings  162  and  164 . Paired connector openings  160  are disposed between the flange and the opening. Openings  162  and  164  are spaced apart to align with standard grill holes so that grill  32  may be adjustably mounted on the frame. For example, in FIGS. 12 and 14, grill  32  is attached to frame  102  with connectors  170  disposed in opening  162  on the left hand side and opening  164  on the right hand side. This configuration allows grill  32  to cover an imperfection  172  disposed on the right hand side of the opening where cover member  31  has been cut too short. In FIGS. 13 and 15, imperfection  172  is disposed on the left hand side and grill  32  is thus moved over by switching connector openings. In other embodiments, grill  32  may have openings that align with both openings  162  or both openings  164 . Pairs  160  thus allow different grills  32  to be used with frame  102 . 
     In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. 
     Moreover, the description and illustration of the invention is an example and the invention is not limited to the exact details shown or described.