Abstract:
The present invention provides an air duct registrer for adding forced air (heat, air conditioning), exhausting air or simply to balance air quality. The air duct register has a manifold and is designed with a removable manifold collar connectible to the flexible or rigid duct. The manifold has thumb cam fasteners to provide ease of installation from below the finished ceiling. With the duct in place above the ceiling elevation, the appropriate opening can be cut and all connections can be made below ceiling elevations via the manifold collar opening. The duct is routed through the manifold opening and connected onto the manifold collar retainer barbs. The manifold collar plate can then be snapped securely into the manifold. The grille then slides into the manifold and is pushed tight to the finished ceiling.

Description:
This application claims priority of Provisional Patent Application 60/463,701 filed on Apr. 17, 2003. 

   FIELD OF THE INVENTION 
   The present invention relates to air duct registers, in particular to air duct registers installed into ceilings for the purpose of heating, cooling and ventilating areas. 
   BACKGROUND OF THE INVENTION 
   Air conditioning and/or heating ducts are often installed above the ceiling in buildings. The supply and return ducts are generally disposed above the level of the ceiling whether it is a sheet rock (gypsum board) ceiling, or a suspended ceiling or any other type ceiling. These main supply and return ducts usually communicate with the interior of the room through vent assemblies that are supported by the ceiling material or within a framed section of a suspended ceiling. Installing the air duct registers in above described ceiling applications can be very difficult, time consuming and frustrating for the installer. 
   One problem associated with securing a register to the end of a duct is the securing of the register to the ceiling material or to the suspended ceiling material. One reason for this problem is that ceiling materials such as sheet rock, thin paneling, or plaster are generally incapable of securely holding a fastener which holds the register in place in the ceiling. Over time the ceiling material weakens and eventually breaks apart or splinters. 
   Another problem encountered is the actual connection of the ductwork to the air duct register. Once the ceiling is in place, the installer is working blindly to connect the end of the duct with the register. 
   SUMMARY OF THE INVENTION 
   It is the intent of the present invention to provide an air duct register that addresses the aforementioned concerns. 
   According to the invention, an air duct register is provided for use in a finished ceiling in a room for connection to a flexible duct located above the ceiling. In one aspect of the invention, the air duct register includes a manifold housing adapted for connecting to the flexible duct wherein the housing provides a fluid passageway from the duct to the room. The air duct register also includes a ceiling clamp operably associated with the manifold housing for attaching the manifold housing within a hole of the ceiling wherein the ceiling clamp has an actuator accessible from below the finished ceiling. 
   In another aspect of the invention, the air duct register includes a removable manifold collar releasibly attachable to the manifold housing and also releasibly attachable to the flexible duct. 
   In another aspect of the invention, the manifold housing has a first access opening at one end of the housing positionable in the hole in the ceiling and a second access opening in a sidewall of the housing positioned 90° from the first access opening and wherein the removable manifold collar is releasibly attachable to the housing within the second access opening. 
   In yet another aspect of the invention, the air duct register further includes a rotatable door releasibly attachable to the manifold collar wherein the door is positionable between a fully open and a fully closed position for regulating the air through the passageway formed by the manifold. 
   The present invention provides for a tool-free installation of the air manifold diffuser for adding air movement, exhausting air, or balancing air pressure in a room. The present invention can be used for new construction as well as retrofit applications. 
   Other applications of the present invention will become apparent to those skilled in the art when the following description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein: 
       FIG. 1  is a schematic view of an air duct register according to the present invention installed in a ceiling. 
       FIG. 2  is a perspective view of a manifold of the present invention having a clamp assembly for the air duct register; 
       FIG. 3  is a perspective view of the clamp assembly; 
       FIG. 4  is a perspective view of a duct collar for the air duct register; 
       FIG. 4   a  is an elevational view of the rear wall of the duct collar; 
       FIG. 5  is a perspective view of a grille or diffuser for the air duct register; 
       FIG. 6  is a perspective view of an end of a duct connecting to the duct collar; 
       FIG. 7  is a schematic view of a second embodiment of the air duct register having a rectangular configuration; 
       FIG. 8  is perspective view of a rotating door connectible to the duct collar in the partially open position; 
       FIG. 9  is a perspective view of the duct collar having the rotating door in the closed position connected thereto; and 
       FIG. 10  is a perspective view of a fully assembled air duct register without the optional door. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Referring to one aspect of the invention,  FIG. 1  shows an air duct register  10  for installation in a finished ceiling  12  is shown therein. The finished ceiling  12  can be made of sheet rock (gypsum board), thin paneling, plaster, or other conventional material. The air duct register  10  is provided for connection to a flexible or rigid duct  14  located above the ceiling  12 . The air duct register  10  receives conditioned air from the flexible duct  14  and channels the conditioned air through a grille or diffuser  16 .  FIGS. 2–5  and  FIG. 8  show components for the air duct register of the present invention. The air duct register  10  includes a manifold  18  having a clamp assembly  20  connected thereto. The air duct register  10  of the present invention also includes a separate piece  22  as well as the grille or diffuser  16 . The piece  22  may optional mount a revolving or rotating door  24  as shown in  FIGS. 8 and 9 . The aforementioned components are made of plastic material to provide a lightweight, inexpensive air duct register that improves air flow, reduces sound and lowers static pressures. 
   Referring next to  FIGS. 2 and 3 , there is shown the manifold which consists of a manifold housing  26  having an essentially dome-shaped configuration. The dome-shaped manifold housing  26  has a flange  28  extending around the periphery of the bottom of the housing  26 . The outer periphery  30  of the flange  28  is used as a template for marking the required hole in the ceiling as will be discussed further hereinafter. The inner periphery  32  of the flange  28  defines bottom opening  32  extending into the interior  34  of the dome-shaped housing  26 . The housing  26  also has a side access aperture  36  sized and configured for receiving the duct collar piece  22  therein to be closed off as shown in  FIG. 10 . The side access aperture  36  is located 90° relative to the flange  28  and the bottom opening  32 . 
   A pair of clamp assemblies  20  are located 180° from each other and located on each side of the side access aperture  36 . Portions of the clamp assemblies  20  are shown in  FIG. 2  and a single enlarged clamp assembly  20  is shown in  FIG. 3 . The ceiling clamp assembly  20  is operable for clamping the ceiling  12  between the flange  28  of the manifold  18  and the clamp assembly  20 . The clamp assembly  20  includes a clamp guide  38 , a thumb cam  40  having an integrally threaded stem  42  and a ceiling clamp  44 . The clamp guide  38  is integrally formed with the housing  26 . The clamp guide  38  forms a path for the integrally threaded stem  42 ; and is positioned around the stem  42  for keeping the ceiling clamp assembly  20  in a rotationally fixed position relative to the thumb cam  40 . The ceiling clamp  44  is threadingly engageable with the integrally threaded stem  42  such that when the thumb cam  40  is rotated in one direction, the ceiling clamp  44  moves closer to the thumb cam  40 . When the thumb cam  40  is rotated in the opposite direction, the ceiling clamp  44  moves away from the thumb cam  40 . The ceiling clamp  44  can only move axially away from and toward the thumb cam  40 . The threaded stem  42  has an unthreaded portion  46  positioned adjacent to the thumb cam  40  and located within an aperture for the base  48  of the clamp guide  38  and through the flange  28 . Therefore the thumb cam  40  is located on the opposing side of the flange  28  from the clamp guide  38  so that the thumb cam  40  is visible and accessible to the installer from below the ceiling  12 . The thumb cam  40  is a flat circular disc having a rigid edge to facilitate the installer to manually turn the cam without the use of a tool. The unthreaded portion  48  has a small lip  50  positioned above the base  48  to maintain the thumb cam  40  with its integral threaded stem  42  in position within the clamp guide  38 . Each ceiling clamp  44  has a wing  43  which extends away from the stem  42 . As the thumb cam  40  is rotated, the wing  43  rotates relative to the stem  42  as the ceiling clamp moves axially along the stem  42  to place the wing  43  in engagement with the ceiling material for securing thereto. The wing  43  may also have teeth  45  along its lower edge for further gripping into the ceiling material. 
     FIGS. 4 ,  4   a,    6 , and  9  show the separate cover piece  22 . As will be explained hereinafter, the cover piece  22  provides a mounting means for connecting the flexible or rigid duct  14  to the air duct register  10 . The cover piece  22  includes a tubular collar  52  extending from a wall  54  extending outwardly from the duct collar  52 . The collar  52  defines a center through opening. The circular collar  52  has at least one but preferably a plurality of retainer barbs  56  for holding the flexible ro rigid duct  14  onto the collar  52  without the need for a hose clamp or other separate tool. Inset from each retainer barb  56  along the periphery of the collar  52  are small apertures  58  for receiving clips to hold an optional door  24 , as will be discussed further hereinafter. A second wall  60  integrally connected to a first wall  54  and positioned 90° relative to the first wall  54  has semi-circular configuration for corresponding to the domed exterior configuration of the housing  26 . The peripheral edge of the second wall  60  forms a groove  62  for receiving a pair of ledges  37  that extend in from the side opening  36  of the housing  26 . A central clip  64  formed in the center of the peripheral edge of the second wall  60  of the cover piece  22  corresponds for latching into a cutout  35  formed between the pair of ledges  37  in the manifold housing  26 . Positioning the pair of ledges  37  within the groove  62  and attaching the clip  64  into the cutout  35  cooperates to secure the cover piece  22  covering the side aperture  36  of the housing  26 . 
   The tubular collar  52  of the cover piece  22  defines a tubular passageway to allow regulated air to be moved between the room and the air duct  14  via the manifold housing  26 . The passageway formed by the tubular collar  52  may optionally be opened or closed by a door assembly  66 . The door assembly  66  is best shown in  FIG. 8 . The door assembly  66  includes a ring  68  defining a central passageway therebetween and a circular planar door  24  sized so that the door  24  closes the passageway through the ring  68 . The door  24  has pins  72  extending from the circumferential sides of the door and positioned 180° from each other. The pins are rotatably held to the ring and maintained in position in a gate  74  located adjacent to each pin  72 . The door  24  is movable to rotate 90° from a fully closed position through a fully open position. The door assembly  66  is connected to the collar  52  by means of tabs  76 . As shown in  FIG. 4   a,  the inner side of the first wall  54  has a circumferential recess  80  concentratric with the circular flange  52 . The circumferential recess  80  is sized for receiving the ring  68  of the door assembly  66 . The recess  80  has a plurality of through slots  58  for receiving the tabs  76  of the door assembly  66 . To properly align the door assembly  66  within the recess  80 , the recess includes a rib  82  for alignment with a corresponding slot  84  in the outer surface of the ring  68 .  FIG. 9  shows the door assembly  66  assembled to the collar  52  with the door  24  closing the passageway. As also shown in  FIG. 9 , a supporting rib  53  may be integrally formed along the first wall  54  of the duct collar piece  22  from the circular collar  52  to the second wall  60  to provide additional strength to the duct collar piece  22 . 
   The air duct register  10  of the present invention further includes a grille or diffuser  16 . The grille or diffuser  16  is shown in  FIGS. 1 and 5 . The grille  16  includes a plurality of spring clips  86  for releasably attaching the grille to the manifold housing  26 . The grille  16  covers the first access opening  32  of the manifold housing  26 . The grille  16  also includes a plurality of vent openings  88  for passing the conditioned air from the flexible or rigid duct  14  into the room. 
   The air duct register  10  can be easily installed into any finished ceiling  12 . The flange  28  of the housing  26  can be used as a template for sizing a hole to be cut into the ceiling  12 . The cut for the hole  17  should be approximately ¼ inch inside the template circle. The round manifold housing  26  is inserted through the cutaway portion  17  of the ceiling  12  positioning the first access opening  32  parallel to the ceiling  12 . The round manifold housing  26  has a flange  28  having a perimeter with a larger diameter than the round manifold housing  26 . The flange  28  is positioned adjacent the finished ceiling  12  when the air manifold assembly  10  is fully installed. The flange  28  prevents the air manifold assembly  10  from completely passing through the cutaway portion  17  of the ceiling  12 . The clamp assembly  20  for releasably locking the air manifold assembly housing  26  with respect to the finished ceiling  12  is accessible from underneath the ceiling  12  by reaching up to the exposed thumb cams  40  of the clamp assembly  20 . The thumb cams  40  can be tightened manually by hand or with a use of a screw driver in the screw driver slot  90 . By tightening the thumb cams  40 , the ceiling clamps  44  rotate into engagement with the ceiling material while the teeth  45  grip into the ceiling material. 
   Once the manifold  18  is installed in the ceiling  12 , the duct  14  is brought through the manifold  18  via the much larger side access opening  36  and through the bottom opening  32 . The duct  14  is then attached to the collar  52 , as shown in  FIG. 6 . The cover piece  22  is then pushed up through the lower access opening  32 , aligned with the opening  26  and pushed against the inside of the housing  26  and attached to housing  26  in position covering the side access opening  30  as discussed supra. 
   Finally, the grille  16  is releasably snap-locked onto the flange  28  of the manifold housing  26 .  FIG. 10  shows an assembled air duct register  10  without the door assembly  66 . 
   The air duct register of the present invention is designed to maximize air flow performance over more conventional sheet metal designs. By utilizing plastic materials and injection molding processes it is possible to radius and smooth the shape of the 90° passageway in the manifold  18  which improves air flow, reduces sound and lowers static pressures. 
   The air duct register of the present invention is further designed with the do-it-yourself home owner handyman in mind. The air duct registers are designed for ease of installation requiring no tools to assemble. The air duct register can be installed into drywall, drop, wood or any finished standard or cathedral ceiling with a minimum clearance of 7-1½ inches from ceiling to top of joist. Once duct  14  is attached, the cover piece  22  can be pushed up into the housing  26  and over the opening  36  and connected to the housing  26  in that position. There is no need to crawl into attic or ceiling to attach clamps or duct elbows to the duct  14 . 
   The air duct register of the present invention can also be used in compliance to building codes requiring balancing of room-to-room air pressures. Two or more units can be connected together to improve room-to-room imbalanced HVAC system air pressures. 
   While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law. One such variation is shown in  FIG. 7 , where the manifold housing  26  has a rectangular shape with a corresponding shaped first access opening  32 .