Patent Publication Number: US-11378301-B2

Title: Access panel and diffuser installation

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to installation of ceiling access panels and diffusers, such as those used in air conditioning and air circulating systems. 
     BACKGROUND OF THE INVENTION 
     Ceiling air diffusers serve as air inlets for supplying air to a room. The diffuser causes the air to travel radially outwards and substantially horizontally along the ceiling of the room. This keeps the air supplied from the diffuser, which is typically cooled by an air conditioning system, from simply dropping directly downwards from the diffuser. This serves to distribute the air and avoids causing discomfort to any occupants of the room who happen to be directly below the diffuser. 
     SUMMARY OF THE INVENTION 
     The present invention relates to methods of installation of ceiling access panels and diffusers, such as those used in air conditioning and air circulating systems, as is described more in detail hereinbelow. 
     There is provided in accordance with an embodiment of the present invention a method including providing a frame which includes a base portion and an outer perimeter portion that protrudes outwards from the base portion, placing a metal flange placed adjacent the outer perimeter portion of the frame, and locating a portion of the metal flange that protrudes outwards of the outer perimeter portion between a ceiling stud of a ceiling and a gypsum board, forming an opening in a gypsum board to accommodate an access panel or a diffuser, and installing a fastener through the gypsum board and the metal flange into the ceiling stud, thereby attaching the gypsum board to the ceiling stud. 
     The opening may be formed in the gypsum board either prior to or after fastening the gypsum board to the ceiling stud. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will be understood and appreciated more fully from the following detailed description taken in conjunction with the drawings in which: 
         FIG. 1  is a simplified illustration of an installation of an access panel or diffuser in a ceiling, in accordance with an embodiment of the present invention; 
         FIG. 2  is a simplified illustration of an installation of a diffuser in a ceiling, in accordance with an embodiment of the present invention; and 
         FIGS. 3A-3F  are simplified illustrations of an installation of a diffuser in a ceiling, in accordance with another embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     Reference is now made to  FIG. 1 , which illustrates an installation of an access panel or diffuser  10  in a ceiling, constructed and operative in accordance with an embodiment of the present invention. 
     The ceiling may include ceiling studs  12 , typically made of metal. A gypsum board (drop panel)  14  (without limitation, such as ⅝″ in thickness) is provided, which will be attached to the ceiling studs (or furring channels or other similar structure)  12 . 
     An opening  15  is cut in the gypsum board  14  to accommodate the access panel or diffuser  10 . A frame  16  is provided, which has an inner perimeter portion  18  that overlies the access panel or diffuser  10 ; a base portion  20 , extending from portion  18 , whose bottom surface will be flush with the gypsum board  14  after installation; and an outer perimeter portion  22  that protrudes outwards from the base portion  20 . A metal flange  24  is placed adjacent (e.g., underneath) the outer perimeter portion  22  of the frame  16 , and a portion of metal flange  24  that protrudes outwards of the outer perimeter portion  22  is located between the ceiling stud  12  and the gypsum board  14 . The metal flange  24  may be made of sheet metal, aluminum or other metals. 
     A fastener  26 , such as a drywall screw  26 , passes through gypsum board  14  and metal flange  24  into each of the ceiling studs  12 . Alternatively, the metal flange  24  is first fastened to the ceiling stud with a first set of fasteners (e.g., screws) and then the fasteners  26  are used to fasten the gypsum board  14  into the ceiling stud  12 , with the fastener  26  passing through a different place on the metal flange  24 . The opening  15  may be formed in the gypsum board  14  either prior to or after fastening the gypsum board  14  to the ceiling studs  12 . 
     After fastening the gypsum board  14  to the ceiling studs  12 , joint compound and tape  28  (such as mesh tape) may be applied around the bottom surface all along the perimeter of frame  16 , in preparation for painting or other finishing. 
     Reference is now made to  FIG. 2 , which illustrates an installation of a diffuser  30  in a ceiling, constructed and operative in accordance with an embodiment of the present invention. The installation is similar to the installation described above for the access panel or diffuser  10 , with the following differences described below. 
     The diffuser  30  of  FIG. 2  serves as the frame  16  of  FIG. 1 , except there is no inner perimeter portion  18  of  FIG. 1 . A light fixture  32  (e.g., an LED light fixture) may be optionally installed in diffuser  30 , and may be electrically connected to electrical components disposed in or on a duct takeoff box  34 . The electrical components may include, without limitation, wires  33 , an LED driver  35 , printed circuit boards, etc. The light fixture  32  may be removed to obtain access to the LED driver and an access panel  36  of the box  34 . 
     Reference is now made to  FIGS. 3A-3F , which illustrate an installation of a diffuser  40  in a ceiling, in accordance with another embodiment of the present invention. 
     Referring to  FIGS. 3A and 3B , diffuser  40  includes a frame  42  and a base portion  44 , whose bottom surface will be flush with the gypsum board  14  (shown in  FIG. 3F ) after installation, as in the other embodiments of the invention. As in the other embodiments, an opening is cut in the gypsum board to accommodate the diffuser. A metal flange  48  is attached to the frame  42 . The metal flange  48  may be L-shaped so that one portion (vertical) is attached to frame  42  and another portion (horizontal) serves as the outer perimeter portion of the base portion  44 . 
     Diffuser  40  may be square (although other shapes are contemplated as well) with an outer edge of its opening having a width A (e.g., 12 inches). The frame width may be dimension B (e.g., 17 inches). The border, that is, the flange  48 , creates seamless blending into the gypsum ceiling, and may have width C (e.g., 20 inches). The invention is not limited to the above dimensions. 
     Reference is now made to  FIG. 3C . A plenum box  52  may be assembled with diffuser  40 . The plenum box  52  may be insulated. The plenum box  52  slides into the vertical flanges  48  and is secured with fasteners  50  to the diffuser frame  42 . The height of the plenum box is based on available space, intended air volume, throw, and noise criteria. The plenum box  52  may have a collar  54 . 
     Reference is now made to  FIG. 3D . The plenum box  52  and diffuser  40  are attached to the ceiling frame. The entire assembly is held in its intended place and fasteners  56  are screwed through the metal flanges  48  into the furring channel  12  of the ceiling frame. For larger diffuser sizes and certain site conditions, it may be easier to attach the diffuser to the ceiling frame before attaching the plenum box. 
     Reference is now made to  FIG. 3E , which illustrates the connection of rigid or flexible ductwork  58  to the plenum box  52  before the gypsum board ceiling is in place. 
     In  FIG. 3F , the assembly is affixed to the gypsum board  14  and finish applied as described above. The diffuser  40  creates an edge for receiving normal drywall finishing compound and mesh tape. After proper application and sanding is completed, the diffuser  40  is ready to receive its finish along with the rest of the ceiling.