Patent Publication Number: US-2021190368-A1

Title: Plug for use in a process of forming an insulated register box

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a continuation-in-part of U.S. patent application Ser. No. 17/171,638, filed on Feb. 9, 2021 and entitled “Conveyor Process for Forming an Insulated Register Box”, presently pending. U.S. patent application Ser. No. 17/171,638 is a continuation-in-part of U.S. patent application Ser. No. 16/036,059, filed on Jul. 16, 2018 and entitled “Insulated Register Box and Process For Forming Such Insulated Register Box”, presently pending. U.S. patent application Ser. No. 16/036,059 was a continuation-in-part of U.S. patent application Ser. No. 15/864,612, filed in Jan. 8, 2018, which is a divisional of U.S. patent application Ser. No. 14/668,079, filed Mar. 25, 2015 and entitled “Insulated Register Box”, now U.S. Pat. No. 9,951,969. U.S. patent application Ser. No. 16/036,059 was also a continuation-in-part of U.S. patent application Ser. No. 16/005,235, filed on Jun. 11, 2018 and entitled “Insulated Register Box with the Boot Rail Adapter”, presently pending. U.S. patent application Ser. No. 16/005,235 is a continuation-in-part of U.S. patent application Ser. No. 15/703,436, filed on Sep. 13, 2017, which issued as U.S. Pat. No. 10,648,695 on May 12, 2020 and entitled “Insulated Register Box with Boot Rail Adapter”. U.S. patent application Ser. No. 15/703,436 is a continuation-in-part of U.S. patent application Ser. No. 15/439,454, filed Feb. 22, 2017 and entitled “Process for Forming an Insulated Register Box”, which issued as U.S. Pat. No. 10,309,682 on Jun. 4, 2019 and entitled “Process For Forming an Insulated Register Box”. U.S. patent application Ser. No. 15/439,454 was a continuation-in-part of U.S. patent application Ser. No. 14/668,079, filed on Mar. 25, 2015 and entitled “Insulated Register Box and Method for Forming an Insulated Register Box”, which issued as U.S. Pat. No. 9,951,969 on Apr. 24, 2018. 
    
    
     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 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. In particular, the present invention relates to plugs as used in the conveyor-style process for forming such register boxes. 
     2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98. 
     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 plug for 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 plug for a process for forming an insulated register box which allows multiple systems to be employed in side-by-side relationship. 
     It is another object of the present invention to provide a plug for 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 plug for a process for forming an insulated register box which reduces the amount of effort by the worker in the production of such insulated register boxes. 
     It is a further object of the present invention to provide a plug for a process for forming an insulated register box which has a relatively small footprint. 
     It is a further object of the present invention to provide a plug for a process for forming an insulated register box which reduces the cost required in the production of such register boxes and reduces the amount of labor required for such production. 
     It is a further object of the present invention to provide a plug for a process for forming an insulated register box which prevents the expandable foam material from entering the duct of such insulated register boxes. 
     It is another object of the present invention to provide a plug for a process for forming an insulated register box which reduces the amount of expandable polymeric foam material used in the production of such register boxes. 
     It is another object the present invention to provide a plug for a process for forming an insulated register box which reduces or eliminates any cleaning efforts required for the cleaning of the interior of the duct. 
     It is another object of the present invention to provide a plug for a process for forming an insulated register box which increases the accuracy of the amount of expandable polymeric foam material dispensed into the interior of the register box. 
     It is still another object of the present invention to provide a process for forming an insulated register box which allows the register box to be produced in a conveyor-style fashion. 
     It is still a further object of the present invention to provide a plug for a process for forming an insulated register box which enhances the appearance of the register box. 
     These and other objects and advantages of the present invention will become apparent from a reading of the attached specification and appended claims. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention is a process for use in a process of forming an insulated register box in which the insulated register box has a box and a duct extending outwardly therefrom. The plug comprises a body having at least one side wall, a bottom wall, and a top edge. The body has a ledge extending outwardly of the top edge thereof The bottom wall is adapted to abut an end of a portion of the duct that extends into the interior of the box of the register box. The ledge is adapted to abut an end of the box of the register box opposite the duct. 
     A gasket is affixed to the bottom wall of the body. This gasket is adapted to abut the end of the portion of the duct that extends into the interior of the register box. This gasket is formed of either a polymeric or elastomeric material. 
     The side wall of the body has four side walls arranged in a generally rectangular configuration. The four side walls are tapered so as to narrow toward the bottom wall of the body. The ledge extends outwardly of each of the side walls. The body has a hollow interior. The side walls are rigid. A handle is affixed to the body. This handle is adapted to allow the body to be manually lifted or lowered. The handle extends across the hollow interior of the body so as to have ends affixed to opposite side walls of the four side walls. A flexible plastic sheet underlies the bottom wall and extends over an exterior of the at least one side wall and extends under the ledge of the body. 
     The present invention is also an assembly for forming an insulated register box in which the insulated register box has a box and a duct extending outwardly therefrom. This assembly has a support having an opening therein, a plug having a body having at least one side wall, a bottom wall and a top edge, a plastic sheet underlies the bottom wall and extends over the exterior of the side wall and under the ledge, and an expandable polymeric material bearing against the plastic sheet. The support is adapted to receive the duct of the insulated register box therein. The plug has a ledge extending outwardly of the top edge of the body. The bottom wall is adapted to abut an end of the portion of the duct that extends into the interior of the box of the register box. The ledge is adapted to abut an end of the box of the register box opposite the duct. The expandable polymeric material is adapted to be received in the interior of the register box. 
     A gasket is affixed to a bottom wall of the body. This gasket is adapted to abut the end of the portion of the duct that extends into the interior of the box of the register box. This gasket is formed of a polymeric or elastomeric material. 
     The side wall of the box comprises four side walls arranged in a generally rectangular configuration. The four side walls are tapered so as to narrow toward the bottom wall of the body. The ledge extends outwardly of each of the four side walls. The body has a hollow interior. The side walls are rigid. A handle is affixed to the body. This handle is adapted to allow the body to be manually lowered or lifted. The handle extends across the hollow interior of the body so as to have ends affixed to opposite side walls of the four side walls. 
     The support has a flat top surface. This flat top surface of the support is adapted to allow the bottom of the box of the insulated register box to rest thereagainst. The expandable polymeric material is adapted to bear against the side walls of the body, against the bottom wall of the body, against the portion of the duct that extends into the interior of the insulated register box, and against the inner walls of the register box. 
     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. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a perspective view of the insulated register box that is produced by the process of the present invention. 
         FIG. 2  is a side elevational view of the insulated register box produced by the process of the present invention. 
         FIG. 3  is a plan view of the insulated register box produced as a result of the process of the present invention. 
         FIG. 4  is a cross-sectional view of the insulated register box is produced by the process of the present invention. 
         FIG. 5  shows an initial step in the process for forming an insulated register box. 
         FIG. 6  is an exploded view showing the assembly of components used in the process for forming the insulated register box. 
         FIG. 7  is a side elevational view of the plug of the present invention as used in the process for forming the insulated register box. 
         FIG. 8  is at the upper perspective view of the plug of the present invention as used in the assembly of components of the process for forming the insulated register box of the present invention. 
         FIG. 9  is a cross-sectional view showing the assembly of components of the present invention as used in the process for forming the insulated register box of the present invention. 
         FIG. 10  is a side elevational view showing the process for forming the insulated register box of the present invention. 
         FIG. 11  is a plan view showing the overall process for forming the insulated register box. 
         FIG. 12  is an end view showing the cleaning step in the process for forming the insulated register box. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIG. 1 , there shown the insulated register box  10  as formed in accordance with the process of the present invention. The register box  10  includes a box  12  having side walls  14 ,  16 ,  18  and  20  formed into a generally rectangular configuration. A back wall  22  extends across this generally rectangular configuration. A duct  24  is illustrated as affixed to the back wall  22  so as to open to the interior of the box  12 . The duct  24  includes an open end  26  so as to allow duct  24  to be connected to the HVAC system of a building. Conventionally, the register box  10  will be formed and pieced together through the use of tack welding. In particular, the duct  24  can be tack welded to the box  22 . As such, the duct  24  will have a portion that extends into the interior of the box  12  defined by the side walls  14 ,  16 ,  18  and  20 . 
       FIG. 2  shows a side view of the register box  10 . As can be seen in  FIG. 2 , the side wall  14  is particularly illustrated. The duct  24  is illustrated extending outwardly of the back wall  22 . It can be seen that there is a lip  44  that extends outwardly of the end  46  of the box  12 . The lip  44 , as will be described hereinafter, extends outwardly of a flange  48 . Flange  48  extends inwardly from the side walls  14 ,  16 ,  18  and  20  such that the lip  50  defines an opening  64  which opens to the interior of the box  12 . 
       FIG. 3  is an end view of the register box of the present invention. In  FIG. 3 , it can be seen that the duct  24  is affixed to the back wall  22 . Back wall  22  includes a surface  52  that extends from the opening of the duct  24  to the side walls  14 ,  16 ,  18  and  20  of the box  12 . The expandable polymeric material  60  resides over the surface  52  and extends to the side walls  14 ,  16 ,  18  and  20 . As such, the expandable polymeric material  60  effectively insulates the back wall  22  in the area adjacent to the opening of the duct  24 . 
       FIG. 3  further shows the nature of the flanges  48 . Flanges  48  have a particular width. In accordance with the present invention, the expandable polymeric material  60  will reside against the side walls  14 ,  16 ,  18  and  20  and have a thickness approximately equal to the width of the flanges  48 . The lip  50  is illustrated as extending in transverse relationship from the flange  48 . 
       FIG. 4  is a cross-sectional view of the register box  10  of the present invention. As can be seen in  FIG. 4 , the expandable polymeric material  60  is illustrated as positioned against the side walls  14  and  16 . A similar configuration will occur with respect to the side walls  16  and  20 . The expandable polymeric material  60  is illustrated as having a thickness approximately equal to the width dimension of the flange  48 . The flange  48 , along with the lip  50 , defines an opening  64  that opens to the interior of the box  12 . The expandable polymeric material  60  also has a portion that resides against the inner surface of the back wall  22 . This portion  60  extends from the side walls  14  and  18  so as to bear against the portion  61  of the duct  24  that extends into the interior of the box  14 . 
     In this configuration, the expandable polymeric material  60  can 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 box  10 . The insulation created by the expandable polymeric material  60  does not require any alterations in the structure of the box  12  or of the duct  24 . The insulation material causes the register box  10  to be very energy-efficient. 
     In  FIG. 4 , it can be seen that there is no expandable polymeric material located on the inner wall  68  of the duct  24 . If any expandable polymeric material would enter the duct  24  or reside on the inner wall  68  of the duct  24 , it could hamper air circulation. Any expandable polymeric material that enters the duct  24  would detract from the appearance of the insulated register box  10 . Furthermore, any expandable polymeric material that should leak into the interior of the duct  24  will create in uncertainties as to the amount of the amount of material that should be introduced into the interior of the register box so as to fully insulate the walls of the register box. If an excessive amount of expandable polymeric foam material leaks into the interior of the duct, less material will reside on the interior of the insulated register box. This can hamper the insulating qualities of the register box. Additionally, if any expandable polymeric material should leak into the interior of the duct, it will be necessary to add personnel in order to clean and scrape this material from the interior of the duct. This increases time and labor required for the production of the insulated register box. It has also been found that it is possible that, during the removal of such material, the insulation on the interior of the register box could tear. Ideally, the prevention of expandable polymeric foam material from entering the interior of the duct can result in uniform amounts of expandable polymeric material being introduced. 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 duct  24 . Since the expandable polymeric material  60  extends to the opening  64  that is defined by the lips  50  and the flanges  48 , 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 duct  24  is blocked by portion  61  of the duct  24 . The blocking of the expansion of the expandable polymeric material into the interior of the duct will be further blocked by the plug as used in the process of the present invention, to be described hereinafter. As such, the blocking of this expandable polymeric foam material from entering the interior of duct allows the interior of the duct to be more aerodynamic, reduces labor and material cost, improves uniformity, improves the aesthetic appearance of the register box, and reduces costs. 
       FIG. 5  shows an initial step in the process of the present invention. In  FIG. 5 , it can be seen that there is a supply of expandable polymeric material  70  that is connected by a conduit  72  to a foam gun  74 . A pump can be used in association with the conduit  72  and/or the supply  70  in order to allow the gun  74  to spray the expandable polymeric material  76  into the box  12  of the register box. In particular, it can be seen that the expandable polymeric material  76  is generally introduced into a corner  80  between one of the side walls  14 ,  16 ,  18  and  20  and the back wall  22 . The portion  61  of the duct  24  extends into the interior  78  of the box  12  so as to resist the flow of expandable polymeric material into the interior of the duct  24 . The small amount of expandable polymeric material that is placed into the interior  78  of the box  12  will suitably expand so as to cover the necessary area in order to create the insulation shown in  FIG. 4 . 
       FIG. 6  shows an exploded view showing an assembly  82  of the various components to be introduced into the conveyor system of the present invention. The assembly  82  includes the register box  10  having the duct  24  extending outwardly of the box  12 . The duct  24  has portion  61  extending into the interior of the box  12 . A support  84  is shown below the register box  10 . The support  84  can be a metallic or wooden block that has an opening  86  formed therein. Opening  86  is sized and shaped so as to receive the duct  24  therein. The back wall  22  of the register box  10  will rest on the top side  88  of the block  84 . As such, this provides a strong and steady support for the register box  10  during the processes of the present invention. 
       FIG. 6  shows that the interior  78  of the register box faces upwardly toward an end  90  opposite to the back wall  22 . In order to form the insulation  60 , initially, a plastic sheet  92  will be placed over the upper end  90  of the box  12 . The plug  94  of the present invention will then be inserted into the interior  78  of the box  12 . After the plug  94  is inserted into the box  12 , the plastic sheet  92  will envelop the exterior surface of the plug  94  so as to be interposed between the expandable polymeric material  60  and the exterior surface of the plug  94 . In essence, this plastic sheet  92  provides a lining or a barrier so as to allow the plug  94  and plastic sheet  92  to be easily removed after the expandable polymeric material  60  has expanded and cured. 
       FIG. 6  further shows that the plug  94  has a ledge  96  that extends outwardly from the remainder of the body. This ledge  96  will be placed over the end of the box  12  and over that portion of the plastic sheet  92  that extends outwardly over end  90  of the box  12 . Ultimately, this creates a sandwiched configuration which will allow the plug and assembly of the present invention to form the insulated register box. A gasket  75  is affixed to the bottom wall of the plug  94 . Gasket  75  can be formed of an elastomeric or polymeric material. Ultimately, the plastic sheet  92  will be interposed between the bottom of the gasket  75  and the end of the portion  61  of duct  24 . The resiliency of the gasket  74 , in combination with the compressive forces of the conveyor system (to be described hereinafter), will tend to “mold” the gasket  75  around the end of the portion  61  of duct  24  so as to prevent the expandable polymeric material  60  from entering into the interior of the duct  24 . 
       FIG. 7  shows an end view of the plug  94  of the present invention. It can be seen that the plug  94  has a generally tapered outer surface  95 . This tapered outer surface  95  will taper so as to narrow in diameter toward the bottom wall  97 . Ledge  96  is at the wide end of the tapered exterior surface  95  of the plug  94 . The underside  99  of the ledge  96  will bear against the plastic sheet  92  during the formation of the insulated register box  10  of the present invention. It can be can be seen that the gasket seal  75  is affixed to the bottom  97  of the plug  94 . The gasket seal  75  extends across the bottom  97  of the plug  94 . As such, this provides a surface that can bear against the end of the duct that extends into the interior of the register box  10 . The gasket  75  is illustrated as affixed to the bottom wall  97  of the plug  94 . The tapered exterior surface  95  of plug  94  facilitates the ability to remove the plug  94  once the expandable polymeric material  60  envelops the plastic sheet and this tapered exterior surface  95 . 
       FIG. 8  is a perspective view showing the interior of the plug  94  of the present invention. As can be seen, plug  94  can be formed of a plastic, aluminum or steel material. The exterior surface  95  is illustrated as tapering downwardly toward the bottom  97 . The interior  101  is hollow. Strut  103  extends across the hollow interior  101 . Strut  103  enhances the structural integrity of the plug  94  and enhances the ability to manipulate the plug during installation and removal. The ledge  96  extends outwardly around the perimeter of the plug  94  at the upper end of the plug  94 . The strut  103  also facilitates the ability to remove the plug  94  from the assembled configuration once the insulating material is properly formed within the insulated register box  10 . The gasket seal  75  is affixed against the bottom  97  of the plug  94 . 
       FIG. 9  shows the assembly  111  of the present invention. The assembly  111  is adapted to allow the insulated register box  10  to be formed. The insulated register box  10  includes the box  12  and the duct  24 . The duct  24  has portion  61  that extends into the interior of the box  12 . Ultimately, the duct  24  will terminate at end  63 . The box  12  includes a back wall  22 , side walls extending upwardly from the back wall  22 , and a top surface  90 . The expandable polymeric foam material  60  is illustrated as positioned within the interior of the box  12 . 
     The assembly  111  of the present invention includes a support  84  having an opening  86  extending into the interior of the support  84  from the top  88  thereof. Opening  86  receives the duct  24  therein. The back wall  22  of the box  12  will rest on the top  88  of the support  84 . The plug  94  is introduced into the interior of the box  12  prior to the expansion of the expandable polymeric material  60 . Plug  94  has gasket  75  located at the bottom  97  thereof. Plug  94  has a tapered outer surface  95  extending upwardly from the bottom wall  97 . The ledge  96  will extend radially outwardly at the top of the plug  94  so as to overlie the top  90  of the box  12  of the insulated register box  10 . It can be seen in  FIG. 9  that the handle (or strut)  103  is positioned adjacent to the top of the plug  94 . The plastic sheet  92  and envelops the plug  94 . In particular, the plastic sheet  92  will extend between the gasket  75  and end  93  of duct  24 . The plastic sheet  92  will also extend between the tapered outer surface  95  of the plug  94  and the expandable polymeric material  60 . The plastic sheet  92  will also underlie the ledge  96  extending outwardly at the top of the plug  94 . As such, upon removal, the plastic sheet  92  will allow the plug  94  to easily separate from the expandable polymeric material  60 . 
     In  FIG. 9 , is important to see that the gasket  95  establishes a tight seal between the plug  94  and the end  93  of the duct  24 . This is very important so as to prevent the expandable polymeric material  60  from entering the interior of the duct  24 . This tight seal around the circumference of the end  93  of duct  24  avoids any leakage of material into the interior of the duct  24 . Since the intrusion of expandable polymeric material  60  into the interior of the duct  24  is prevented by the present invention, there is no need for subsequent cleaning actions for the removal of the residual foam from the interior of the duct  24 . Also, this assures that the uniform introduction of expandable polymeric material into the interior of the box  12  will create uniform results. The appearance of the insulated register box  10  is improved by avoiding the appearance of scraped material in the interior of the duct  24 . This also avoids those problems in which the expandable polymeric material  60  is damaged during the cleaning of the interior of the duct  24 . As such, plug  94 , along with the assembly  111 , of the present invention provides cost savings, reduction in material usage, reduced labor costs, and improved aesthetics. 
       FIG. 10  shows the assembly  111  residing at an end  100  of a lower conveyor  102 . As can be seen, the duct  24  is received in the opening  86  of the support  84 . The plug  94  has been received in the interior  78  of the box  12 . The plastic sheet  92  surrounds the exterior of the plug  94  and is interposed between the expandable polymeric material  60  and the exterior of the plug  94 . The conveyor  102 , as shown in  FIG. 10 , will cause the relatively rigid belt  104  thereon to move in a generally clockwise manner. As such, the assembly  111  will move from the position at the end  100  of the conveyor  102  to a position located between conveyor  102  and conveyor  106 . Conveyor  102  has a length slightly longer than the length of the conveyor  106  so as to allow the placement of the plug  96  onto the assembly  92 . Ultimately, the assembly  111  will enter the area between the conveyors  102  and  106 . The rigid nature of the belt  104  of conveyor  102  and belt  108  of conveyor  106  will cause the gasket seal  97  of plug  94  to compress against the end  63  of portion  61  of the duct  24 . The ledge  96  will compress against the end  90  of the box  12 . This compression will allow the expandable polymeric material  62  expand and cure while avoiding intrusion into undesired spaces within the register box. The tight relationship between the plug  94  and the end of the portion  61  of the duct  24  will prevent the expandable polymeric material  60  from entering the interior of the duct  24 . This avoids those circumstances where the worker places the plug  94  too loosely onto the assembly such that expandable polymeric material leaks into the interior of the duct. Similarly, the tight relationship between the belt  108  and the plug  94  will cause plug  94  to always bear with constant force against the end  90  of the box  12  so as to prevent the expandable polymeric material  60  from escaping into the interior  78  of the box  12 . 
     As can be seen in  FIG. 10 , the assembly  111  will continue to move along the conveyors  102  and  106  in a tightly compressed configuration. The length of the conveyors  102  and  106  is configured so as to allow for a proper amount of curing time. In actuality, workers will continue to place separate assemblies  111  one after the other upon the conveyor  102  so that the process is a continuous process. The assemblies  111  will be spaced from one another throughout their travel with the conveyors  102  and  106 . The arrow  110  illustrates the direction of movement of the assemblies  82  on the parallel conveyors. 
     It is important to note that the belt  108  of conveyor  106  moves in a counter-clockwise direction. As such, when the assembly  111  reaches the end of travel between the conveyors  102  and  106 , the assembly can be removed. As such, materials can be returned back to the end  100  for use by the worker. As can be seen in  FIG. 10 , when the assembly  111  reaches the end of travel, the plug  94  is removed from the interior of the box  12 . This can be placed on the top of the belt  108  and returned back to the beginning of the conveyor. Similarly, the support  84  can also be placed on the belt  108  and returned back to the original position. As such, as the insulated register box is delivered to the opposite end  112  of the conveyors  102  and  106 , the return action of the conveyor  106  will 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 housing  113  is positioned over the conveyors  102  and  106 . There is an upper portion  115  of the housing  113  that has openings  117  and  119  opening to the interior of portion  115 . A pipe  121  is connected to the openings  117  and  119 . Ultimately, a vacuum is applied to the pipe  121  so as to create a suction on the interior of the portion  115  of housing  113 . As such, gases will escape from the interior of portion  115  by virtue of this vacuum suction. Similarly, another portion  123  of the housing  113  underlies the conveyor  104 . Openings  125  and  127  serve to open to the interior of portion  123 . Openings  125  and  127  are connected to the pipe  129 . Once again, a suction is applied to the pipe  129  so as to draw any vapors from the interior of the portion  123  of housing  113 . The suction facilitates drying and curing of the expandable polymeric material. This action is shown by the arrows in fit in  FIG. 10 . 
     On occasion, foam and debris  131  may form on the lower surface of the conveyor  106 . To remove this foam and debris  131 , a scraper  133  is affixed to the housing  113  at the end of the conveyor  106 . Scraper  133  will separate the foam and debris  131  such that the foam and debris can fall downwardly and be received within a receptacle  135  therebelow. Receptacle  135  can contain an auger conveyor  137  so as to transport the separated foam and debris to a remote location. Similarly, conveyor  104  also can have debris  131  on the upper surface thereof Another scraper  139  is affixed to the housing  113  adjacent to the end of the conveyor  104 . Scraper  139  will once again separate the foam and debris  131  from the conveyor  104  such that the foam and debris  131  falls downwardly into the receptacle  139 . This foam and debris is then transported to the receptacle  135  and then transported by the auger conveyor  137  to a remote location. 
       FIG. 11  shows a plan view of a layout  124  for the assembly of register boxes. As can be seen in  FIG. 11 , the various register boxes  122  are arranged in spaced relationship upon the conveyor  124 . In actual operation, the register boxes  122  will be placed in staggered relation to register boxes  126 . As such, there are two rows in staggered relation that move from end  128  to end  130  of the conveyor  124 . Each of the register boxes  122  and  126  is configured in the manner shown by the assembly  111  of  FIG. 9 . The staggering of the register boxes allows for ease of travel from end  128  to end  130  and such that the conveyor belts will can distribute an even and constant amount of pressure across the surfaces of the assemblies. Arrow  132  illustrates the direction of travel of these register boxes. 
     In  FIG. 11 , there is a work pallet  134  and a foam gun  136  positioned adjacent to the end  108  of the conveyor  124 . As such, a worker can stand adjacent to the end  128  of the conveyor  124  and have an arrangement of the fabricated register boxes at one side on the work pallet  134  and the foam gun  136  at the other side. Typically, the work pallet  134  will have a stack of the fabricated register boxes. The foam gun  136  allows 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 end  128  of conveyor  124  so as to carry out the formation of the insulated register box of the present invention. 
       FIG. 11  shows that the ability to produce register boxes is enhanced by the ability to have additional conveyors  140 ,  150  and  160  in side-by-side relationship. As such, each of these conveyors  124 ,  140 ,  150  and  160  can be used for additional production of insulated register boxes. Under those circumstances where demand is great and greater production is required, all of the conveyors  124 ,  140 ,  150  and  160  can be used. Under reduced demand and lower production requirements, only one or a few of such conveyors need to be used. Each of the conveyors  124 ,  140 ,  150  and  160  will have an identical construction. 
     Each of the conveyors  124 ,  140 ,  150  and  160  will have their ends delivering product to transverse conveyor  170 . The transverse conveyor will deliver product from the end  130  of conveyor  124  toward the cleaning conveyor  180 . Arrow  182  illustrates the direction of movement of the various insulated register boxes exiting the particular conveyors.  FIG. 11  also shows the auger conveyor  137 . Auger conveyor  137  serves to receive the foam and debris  131  from each of the conveyors  104  and  106 . The auger conveyor  137  will also receive the foam and debris from the conveyors  140 ,  150  and  160 . The auger conveyor  137  will then transport the foam and debris to a remote location  141 . 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 conveyor  137 . As such, the conveyors will remain clean throughout their continuous use. 
     A worker will reside at end  182  of the conveyor  180 . As such, the arrangement and order of insulated register boxes being delivered to the transverse conveyor  170  is not important. Ultimately, these insulated register boxes will funnel in the direction toward the surface of the conveyor  180 . The worker at the end  182  will 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 conveyor  180  to brushes  184 . Brushes  184  are 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 end  186  of the cleaning conveyor  180 . 
       FIG. 12  illustrates the configuration of the brushes used for the cleaning of the duct  300  of register box  302 . In particular, it can be seen that the cleaning brushes  184  are supported by frame  186  above the cleaning conveyor  180 . The cleaning brushes  184  can be suitably motorized so as to rotate for the proper cleaning of the duct  300 . Alternatively, the motion of the insulated register box  302  on the cleaning conveyor  180  can create enough motion out of stationary cleaning brushes  184  to effectively remove the expandable polymeric material from the exterior of the duct  300 . It can also be seen that there are also cleaning brushes  185  and  187  located on opposite sides of the body of the insulated register box  302 . As such, while the cleaning brushes  184  serve to clean the exterior surfaces of the duct  300 , cleaning brushes  185  and  187  serve to clean the exterior surfaces of the body of the insulated register box  302 . As such, the process provides a clean and debris-free register box. 
       FIG. 12  also shows that there is a motor  304  associated with a shaft  306  that can drive the movement of the cleaning conveyor  180 . The shaft  306  and the motor  304  supported by structure  308  above an underlying surface  310 . Similar mechanisms can be used in association with the various conveyors described herein previously. The support of the cleaning brushes  184  to the side of and above the cleaning conveyor  180  avoids any interference with the proper motion of the cleaning conveyor  180  and avoids any interference with the movement of the body  312  of the insulated register box  302 . 
     The foregoing disclosure and description of the invention is illustrative and explanatory thereof. Various changes in the details of the illustrated construction can be made within the scope of the appended claims without departing from the true spirit of the invention. The present invention should only be limited by the following claims and their legal equivalents.