Abstract:
Disclosed herein is an insert for aligning a register with a boot of an HVAC system through a cavity in an intermediate construction surface, the insert comprising: an upper portion; a lower portion having a flange, the lower portion engaging with the register; and a central cavity, wherein the upper portion of the insert protrudes through the cavity in the intermediate construction surface and engages with the boot; the flange is flush with a finished surface of the intermediate construction surface, and the register covers the central cavity of the insert.

Description:
[0001]    This application claims priority to U.S. Provisional Application Ser. No. 61/739,673 filed on Dec. 19, 2012. This and all other referenced extrinsic materials are incorporated herein by reference in their entirety. Where a definition or use of a term in a reference that is incorporated by reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein is deemed to be controlling. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This disclosure relates to the field of the alignment of a register with a boot of an HVAC system, with an intermediate construction surface between the boot and the register. In particular, it relates to the use of an insert to ensure a snug fit between the register, the intermediate construction surface, and the boot. 
       BACKGROUND 
       [0003]    Many homes have ceiling and/or wall boots (hereon in referred to simply as “boots”) which are installed in the ceiling/walls prior to the installation of either drop ceilings or drywall. These boots (or ducts) are generally affixed to joists with sheet-metal tabs affixed to the side of the boot assembly, or by attaching the boot and/or branch feed-pipe to a sheet-metal bracket or support of some kind. While the boots are generally properly secured, the installation can commonly leave the boot distorted, resulting in major air gaps between the boot and the register. 
         [0004]    Often, the register fails to be properly secured to the boot for a number of reasons. For example, a boot may be installed without mounting tabs. Or, during installation, the boot is stretched and/or distorted so that the register fasteners cannot be readily secured to one or both tabs on the boot. Sometimes, a tradesperson installing the register to the boot will find a makeshift solution in order to attach the register to a solid surface. Even when this step is taken, there is often a significant air gap around the register, allowing the entrance of unfiltered air into the room through the register, or the escape of climate-controlled air (heated/cooled) into the ceiling/attic cavity. In both cases, the efficiency of the HVAC (heating, ventilation and air-conditioning) system is compromised. 
         [0005]    US Patent Publication No. 20130043671 discloses a termination for round ducting and collars for diffusers and grills used in air distribution heating, cooling, and ventilation duct systems. In particular, the apparatus disclosed therein, serves as a termination point for a connection of a pipe or duct elbows to a diffuser. The termination point is affixed to vertical or horizontal studs before a finished surface (e.g. a drywall) is installed. 
         [0006]    US Patent Publication No. 20030177724 discloses an H-shaped boot-to-register cover mounting adapter, which provides a “solidly constructed attachment point” for the boot, and a flange or surface for the register to be attached to. The mounting adapter is installed before the finished surface is added to the studs/joists. The device is attached to the studs and the boot is fastened to the inside or outside of the tabs that protrude from the surface facing away from the finished surface. 
         [0007]    U.S. Pat. No. 5,957,506 discloses a sheet-metal insulated register box with an adjustable elbow fitting, A sheet-metal elbow is coupled by direct attachment to a flat sheet-metal air inlet panel of an air distribution boot or register box. The box has a flange plate that is crimped and spot welded over the bottom edge of the boot, making the bottom of the boot rigid. In addition, flange tabs are designed to accommodate a register. The bottom of the flange is designed to protrude into the finished side of the ceiling/wall, and make contact with the register, while the tabs remain on the unfinished side of the ceiling/wall and become attachment points for the register (through the finished surface). 
       SUMMARY OF THE INVENTION 
       [0008]    Disclosed herein is an insert for placement between a boot and a register. An upper portion of the insert attaches to the boot, while a lower portion of the insert attaches to the register. The insert in its general form will first be described, and then its implementation in terms of specific embodiments will be detailed hereafter. These embodiments are intended to demonstrate both principle and optional features of the insert, and the manner of its implementation. The insert in its broadest and more specific forms will then be further described, and defined, in each of the individual claims which conclude this specification. 
         [0009]    In one aspect of the present invention, there is provided an insert for aligning a register with a boot of an HVAC system through a cavity in an intermediate construction surface, the insert comprising: an upper portion; a lower portion having a flange, the lower portion engaging with the register; and a central cavity, wherein the upper portion of the insert protrudes through the cavity in the intermediate construction surface and engages with the boot; the flange is flush with a finished surface of the intermediate construction surface, and the register covers the central cavity of the insert. 
         [0010]    In another aspect of the present invention, there is provided a method of aligning a register to a boot of an HVAC system through a cavity in an intermediate construction surface, the method comprising the steps of: placing an insert between a finished surface of the intermediate construction surface and the register, the insert having an: upper portion; a lower portion having a flange; and a central cavity; inserting the upper portion through the cavity in the intermediate construction surface; placing the flange flush with the finished surface; engaging the upper portion with the boot; engaging the register with the lower portion of the insert; and covering the central cavity of the insert with the register. 
         [0011]    The upper portion on the insert can be attached to one, two, three or four surfaces of the boot. The insert can be attached using methods known in the art. For example, the insert can be attached with screws which are inserted through apertures in the insert, optionally followed by application of a seal to further bind the upper portion to a surface of the boot. The seal can be, for example, duct tape. It is also possible to secure the insert to the boot with a double-sided adhesive and/or a mechanical seal (for example, a gasket). The upper portion can attach to either the inner or an outer surface of the boot. 
         [0012]    The lower portion of the insert comprises a flange that is flush with the intermediate construction surface (e.g. drywall or ceiling) once the insert is secured to the boot. The flange covers any air gaps between the cut-out in the drywall/ceiling and the boot. The register securely connects to the lower portion of the insert, thereby completing the connection between the boot, the insert and the register. 
         [0013]    Where the boot is not directly adjacent an unfinished surface of the intermediate construction surface (say, for example, in the case of a drop ceiling or a wall extension), the insert may be modified to include an extended upper portion to reach through the ceiling/wall surface and into the boot for affixing thereto. The extended upper portion may be fixed, or may include a telescoping element. 
         [0014]    The insert may be made from galvanized steel, extruded plastic, or other suitable material. A few variations of the insert are contemplated. For example, the insert can be combined with an attachable/detachable register (thereby eliminating the need for fasteners between the register and the insert). Other examples include an insert equipped with a separate trim plate/ring that is placed between the intermediate construction surface and the insert—to allow for increased ceiling coverage; or to cover up poorly-designed register cut-outs; or for decorative trim. 
         [0015]    In addition, the insert can have a variety of shapes and sizes, including (but not limited to) circular, oval, four-sided, polygonal, etc. Also, the boot (to which the insert is attached) can have a variety of shapes and sizes. 
         [0016]    As for installation, the insert can be affixed to the boot prior to attachment to the register. Or, where the insert comprises a register, the combined insert/register can be affixed to the boot simultaneously. 
         [0017]    The foregoing summarizes the principal features of the insert and some of its optional aspects. The insert may be further understood by the detailed description of the embodiments which follow. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  illustrates an exploded view of a boot, register, and one embodiment of the insert, while  FIGS. 1A and 1B  respectively illustrate a sectional view along arrows  1 A and  1 B in  FIG. 1  of a boot-insert-register assembly. 
           [0019]      FIG. 2  illustrates an exploded view of a boot, register, and the insert embodiment shown in  FIG. 1 , along with a trim ring/plate.  FIG. 2A  illustrates a sectional view along arrows  2 A in  FIG. 2  of a boot-insert-register assembly. 
           [0020]      FIG. 3  illustrates an exploded view of a boot, register, and a second embodiment of the insert. 
           [0021]      FIG. 4  illustrates an exploded view of a boot, register, and a third embodiment of the insert. 
           [0022]      FIG. 5  illustrates a fourth embodiment of the insert. 
           [0023]      FIG. 6  illustrates a fifth embodiment of the insert. 
           [0024]      FIG. 7  illustrates an exploded view of a boot, register, and a sixth embodiment of the insert.  FIG. 7A  illustrates a sectional view along arrows  7 A in  FIG. 7  of a boot-insert-register assembly. 
           [0025]      FIG. 8  illustrates an exploded view of a boot, register, and a seventh embodiment of the insert. 
       
    
    
     DETAILED DESCRIPTION 
       [0026]    Wherever ranges of values are referenced within this specification, sub-ranges therein are intended to be included within the scope of the disclosure unless otherwise indicated. Where characteristics are attributed to one or another variant, unless otherwise indicated, such characteristics are intended to apply to all other variants where such characteristics are appropriate or compatible with such other variants. 
         [0027]    The following is given by way of illustration only and is not to be considered limitative. Many apparent variations are possible without departing from the spirit and scope of the insert. 
         [0028]      FIG. 1  provides an exploded view of an insert ( 5 ) that attaches to a boot ( 20 ) through a cut-out ( 66 ) in an intermediate construction surface ( 64 ) (e.g. such as a wall or ceiling). The boot ( 20 ) and attached duct ( 63 ) are usually mounted to surrounding joists (not shown) or other construction member. In the embodiment shown in  FIG. 1 , the duct ( 63 ) is attached via a bracket ( 62 ) to surrounding construction member ( 60 ). In addition, the boot ( 20 ) and duct ( 63 ) lie on the unfinished side of the intermediate construction surface ( 64 ). 
         [0029]    The insert ( 5 ) lies on the finished side of the intermediate construction surface ( 64 ), and comprises an upper portion ( 10 ), a lower portion ( 15 ) and a central cavity ( 17 ). The upper portion ( 10 ) attaches to the boot ( 20 ), through cut-out ( 66 ). In the embodiment shown in  FIG. 1 , the upper portion ( 10 ) comprises four panels ( 25 ). Each panel ( 25 ) has one or more apertures ( 30 ) which can receive a fastener (not shown) in order to affix the insert ( 5 ) to the boot ( 20 ). While the embodiments of the insert shown in the figures comprise four panels, it is understood that the insert may comprise any number panels for attachment to a boot. Furthermore, panel apertures are not required, and the panels can have any shape. The lower portion ( 15 ) of the insert ( 5 ) comprises a flange ( 40 ) at the outer perimeter of the insert ( 5 ). The flange ( 40 ) is placed flush against the finished side of the intermediate construction surface ( 64 ), so as to cover any air gaps between the outer perimeter of the boot ( 20 ) and cut-out ( 66 ). This is illustrated in  FIG. 1A  and discussed further below. 
         [0030]    The register ( 45 ) attaches to the lower portion ( 15 ) of the insert ( 5 ) in order to cover the central cavity ( 17 ) from below. As shown in  FIG. 1 , the register can be directly connected to the flange ( 40 ) of the insert ( 5 ) with the use of fasteners ( 50 ), such as, but not limited to, screws. 
         [0031]      FIGS. 1A and 1B  illustrate a sectional view of a register-insert-boot assembly when viewed along arrows  1 A and  1 B, respectively, in  FIG. 1 . In the embodiment shown in  FIGS. 1 ,  1 A and  1 B, the panels ( 25 ) are each placed flush with an inner wall surface of the boot ( 20 ). However, it is understood that the panels can be placed flush with an outer wall surface of the boot. The insert ( 5 ) can be further secured to the surface of the boot ( 20 ) by application of an adhesive or seal to bind one or more panels onto an adjacent surface of the boot ( 20 ). 
         [0032]    The end of the boot ( 20 ) is almost flush with the cut-out ( 66 ). However, the shape of the cut-out ( 66 ) is not always identical with the end-shape of the boot ( 20 ), leaving the possibility of air gaps (not shown) between the cut-out ( 66 ) and the outer perimeter of the end of the boot ( 20 ). In addition, the flange ( 40 ) of the insert is flush with a finished side of the intermediate construction surface ( 64 ). As such, the panels ( 25 ) and the flange ( 40 ) serve to cover any air gaps present between the end perimeter of the boot ( 20 ) and the cut-out ( 66 ). 
         [0033]      FIG. 2  illustrates an exploded view of a register-insert-boot assembly that includes an optional trim ring/plate ( 72 ) placed between the insert ( 5 ) and the intermediate construction surface ( 64 ). The trim ring/plate ( 72 ) may be used when the cutout ( 66 ) is much larger than the exhaust perimeter of the boot ( 20 ). The cutout ( 74 ) of trim ring/plate ( 72 ) has a dimension equal to or greater than that of the perimeter of the end of the boot ( 20 ). Trim ring/plate ( 72 ) is dimensioned to fully cover the cutout ( 66 ) of intermediate construction surface ( 64 ). This is further illustrated in the sectional view of  FIG. 2A , in which the trim ring/plate ( 72 ) is flush with a finished surface of the intermediate construction surface ( 64 ) 
         [0034]      FIGS. 3-8  illustrate further embodiments of the insert. 
         [0035]    In  FIG. 3 , the insert ( 70 ) comprises an upper portion ( 75 ) for attachment to the boot ( 20 ) through the cutout ( 66 ) in the intermediate construction surface ( 64 ); and a lower portion ( 80 ) which comprises a flange ( 85 ); and a register ( 90 ) flexibly attached to the insert ( 70 ). As in the first embodiment, the boot ( 20 ) is mounted onto a surrounding surface construction ( 60 ). 
         [0036]    In the embodiment shown in  FIG. 3 , the register ( 90 ), while attached to the insert ( 70 ), can range from an open position (as shown in  FIG. 3 ), to a closed position where the register ( 90 ) covers the cavity ( 95 ) of the insert ( 70 ). The register ( 90 ) can be secured in the closed position by using tabs ( 100 ) affixed to the flange ( 85 ) of the insert ( 70 ). While tabs are shown, other attaching elements known to a worker skilled in the art may be used. 
         [0037]    The insert ( 70 ) shown in  FIG. 3  attaches to the boot ( 20 ) in a manner similar to that described in  FIG. 1 . The register ( 90 ) is maintained in an open position, as the insert ( 70 ) is secured to the boot ( 20 ), and then subsequently secured in a closed position. Optionally, the flexible attachment may be designed to permit temporary detachment to ease insert installation. 
         [0038]    In  FIG. 4 , the insert ( 105 ) comprises an upper portion ( 110 ) for attachment to the boot ( 20 ), and a lower portion ( 115 ) which comprises a flange ( 120 ); and a receiving portion ( 125 ) for receiving a register ( 130 ). Once the register ( 130 ) slides into the receiving portion ( 125 ) of the insert ( 105 ), it can be secured thereto, for example, by a raised knob ( 135 ) on the register ( 130 ) which fits snugly into an aperture ( 140 ) on the insert ( 105 ). The register ( 130 ) can be secured into the receiving portion ( 125 ) of the insert ( 105 ) by other means, such as, one or more fasteners, one or more clamps, or other securing elements known in the art. As in all embodiments, the boot ( 20 ) is mounted onto a surrounding surface construction ( 60 ). 
         [0039]    In  FIG. 5 , the insert ( 145 ) comprises an upper portion ( 150 ) for attachment to a boot (not shown), and a lower portion ( 155 ) which comprises a flange ( 160 ); and a pair of recessed slots ( 165 , 170 ). The slots ( 165 ,  170 ) are located at opposite longitudinal extremities of the insert ( 145 ). Each recessed slot is closed off at one end ( 175 ). The register ( 180 ) includes a pair of U-shaped tabs ( 185 ,  190 ) also located at opposite longitudinal extremities that are fitted to slide into the respective recessed slots ( 165 ,  170 ). The register ( 180 ) does not slide all the way through the insert ( 145 ), due to the blocked end ( 175 ). Optionally the slots ( 165 ,  170 ) may be continuous (not shown) allowing the tabs ( 185 ,  190 ) to enter their respective slots ( 165 ,  170 ) from either side. Alternatively the slots ( 165 ,  170 ) and tabs ( 185 ,  190 ) may be located along the longitudinal edge of the lower portion of the insert and register, respectively. The register ( 180 ) can be further secured to the insert ( 145 ) by use of a clamp, fasteners, tabs, or the like. 
         [0040]    In  FIG. 6 , the insert ( 200 ) comprises an upper portion ( 205 ) for attachment to a boot (not shown), and a lower portion ( 210 ) which comprises a flange ( 215 ); and a multiplicity of raised tabs ( 220 ) on each longitudinal edge of the flange ( 215 ). Alternatively, the tabs may be located along the shorter edges of the flange ( 215 ). The register ( 225 ) includes an equal number of clip-on tabs ( 230 ), positioned to snap over the raised tabs ( 220 ) located on the insert ( 200 ). The register ( 225 ) is secured onto the insert ( 200 ) by snapping each of the clip-on tabs ( 230 ) onto the respective raised tab ( 220 ). The register ( 225 ) may also have, as an option, a raised perimeter ( 235 ). 
         [0041]      FIGS. 7 ,  7 A and  8  illustrate a separate embodiment of an insert ( 5 ) for use when the boot ( 20 ) is not directly adjacent an unfinished surface of the intermediate construction surface ( 64 ). Examples include a drop ceiling, or a wall extension, wherein the boot is not directly juxtaposed against the new ceiling or wall. 
         [0042]    In  FIGS. 7 and 7A , the insert ( 5 ) now includes panels ( 25 ) that are raised. These panels ( 25 ) are inserted through the intermediate construction surface ( 64 ), for juxtaposition with the inner surface of the boot ( 20 ). As in all embodiments, the boot ( 20 ) is mounted to a surrounding construction member (not shown), such as a joist, or the like. In this arrangement, the boot ( 20 ) is not flush with the intermediate construction surface ( 64 ); rather the boot ( 20 ) is raised above the unfinished side of surface ( 64 ), and there is a physical gap between the two. The flow of air through the boot, however, is contained within the insert panels ( 25 ), and channeled thereby through the boot ( 20 ) and register ( 45 ). 
         [0043]    While  FIGS. 7 and 7A  illustrate a fixed extended set of panels ( 25 ),  FIG. 8  illustrates an embodiment in which the extension is telescopic. The extension includes a base ( 68 ) which is fixed to the flange ( 40 ), and has a continuous perimeter surface. The base ( 68 ) includes one or more apertures ( 69 ), in which tabs (not shown) on telescoping panels ( 25 ) are inserted, so as to prevent telescopic panels ( 25 ) from completely disengaging from base ( 68 ). It is understood that other methods known in the art, can be used to prevent complete disengagement of telescoping panels ( 25 ) from base ( 68 ), as telescoping panels ( 25 ) are raised to engage with the boot ( 20 ), as previously described. Variations permitting disengagement are optional. 
       CONCLUSION 
       [0044]    The foregoing has constituted a description of specific embodiments showing how the device may be applied and put into use. These embodiments are only exemplary. The device in its broadest, and more specific aspects, is further described and defined in the claims which now follow. 
         [0045]    These claims, and the language used therein, are to be understood in terms of the variants of the device which have been described. They are not to be restricted to such variants, but are to be read as covering the full scope of the device as is implicit within the invention and the disclosure that has been provided herein.