Patent Document

RELATED APPLICATION DATA 
       [0001]    The present application claims the benefit of U.S. Provisional Application Ser. No. 61/206,050 filed on Jan. 26, 2009, the disclosure of which is herein incorporated by reference in its entirety. 
     
    
     TECHNICAL FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to the field of heating, ventilation and air-conditioning (HVAC) systems that utilize air registers (also referred to as vents or diffusers) that assist in the transfer of air from ducts into living and work areas within homes or buildings. In particular, the present invention relates to eliminating the transfer of air through inadequately and/or inefficiently designed air registers during times that the transfer of air through a register is undesirable. 
       DESCRIPTION OF THE RELATED ART 
       [0003]    Air forced through heating, ventilation and air-conditioning (HVAC) systems is generally output through ducts to one or more registers (also referred to as a vents or diffusers), which are located in predetermined locations throughout a building. HVAC systems generally have a series of ducts contained within the building&#39;s walls, ceilings and attic crawl spaces. The ducts carry forced air (e.g., heated air or cooled air) to the registers located in the living and/or work areas. The ducts are attached to the back side of an interior surface (e.g. sheetrock, ceiling, wallboard, a finished or un-finished surface, etc.) at openings designed for the register. A register fits into the opening in the wallboard and is attached by several sheet metal screws. 
         [0004]    It is well known to provide dampers in a register to control the flow of air out through a register. Today, it is common for the register to be provided with a plurality of closely spaced louvers that are controlled by an external lever to adjust the louvers in an open position, a closed position or a position somewhere in between open and closed. The closed position of this type of damper is intended to have the louvers closely overlap each other and thus impede the flow of air through the air register. In the closed position, such a register is intended to prevent the escape of air from the HVAC system through the register. Thus, air (e.g., warming air, cooling air) circulated by the HVAC system may be re-directed to warm and/or cool another portion of the house or building. 
         [0005]    One problem with such conventional registers is that even when the louvers are in the closed position air can readily pass through the louvers. Therefore, instead of bypassing the register, as intended by the user, the air escapes the louvers and warms or cools the area in which the register is located, thereby wasting energy. Another problem with such conventional registers is that they are typically made from metal, which acts as a conductor and has very low insulative properties. 
       SUMMARY 
       [0006]    A need exists for a register cover to easily secure to a register with an interface that covers the entire register and any sidewalls of the register in order to prevent heating and/or cooling air forced from a HVAC system from escaping through the register. 
         [0007]    The register cover may be used within residential homes that have HVAC air registers, vents or diffusers. The register cover is intended to eliminate heat loss and cold drafts from leaving and/or entering building spaces (e.g., residential living areas) through the registers in which the register cover is secured. The transfer of air takes place through inadequate and/or inefficiently designed HVAC air registers/vents that are commonly installed in residential homes, as discussed above. 
         [0008]    In one embodiment, the register cover attaches in seconds to the register through the use of magnets. The register cover is made from a plastic material, which may be molded from a plastic composite material, such as, PVC or ABS, for example. The register cover may take the form of a quadrilateral (e.g., square, rectangular, etc.) shape that has a top, bottom and four (4) sides (or side wall) that when put in place, covers the entire register. Alternatively, the register cover may take any desired shaped. When placed over the register, the sides of the register cover come in contact with the surface (e.g., wallboard, ceiling, or other finished or un-finished surface) that surrounds the register. The register cover forms a tight seal over the register, which eliminates the transfer of air from leaving and/or entering register. The register cover is attached to the register through one or more securing elements (e.g., magnets) that form a magnetic draw between the register cover and the register. In one embodiment, there are four (4) securing elements spaced apart in predetermined locations for securing the to register cover to the register. 
         [0009]    One aspect of the invention relates to a register cover including: a base member impervious to air, wherein the base member includes a front surface and a back surface; a side wall extending from the base member along a perimeter of the base member, wherein the side wall and the back surface form a cavity for receiving an associated register, herein the cavity completely covers the associated register including register sidewalls; and a plurality of a securing elements configured along the back surface to secure the base member to the associated register. 
         [0010]    Another aspect of the invention relates to a method for attaching a magnetic register cover to a non-metallic register, the method including: providing a register cover, wherein the register cover includes a base member impervious to air, wherein the base member includes a front surface and a back surface; a side wall extending from the base member along a perimeter of the base member, wherein the side wall and the back surface form a cavity for receiving an associated non-metallic register and the cavity completely covers the associated non-metallic register; and a plurality of a magnets configured along the back surface to secure the base member to the associated non-metallic register; attaching one or more metallic mounts to the associated non-metallic register, wherein the one or more metallic mounts are configured to magnetically engage the magnets of the register cover; and placing the register cover over the associated non-metallic register, wherein the magnets of the register cover secure the register cover to the one or more metallic mounts and the register cover to create an interface between the sidewall and back surface of the register cover and the associated non-metallic register such that forced air is prevented from escaping through the interface. 
         [0011]    These and further features of the present invention will be apparent with reference to the following description and attached drawings. In the description and drawings, particular embodiments of the invention have been disclosed in detail as being indicative of some of the ways in which the principles of the invention may be employed, but it is understood that the invention is not limited correspondingly in scope. Rather, the invention includes all changes, modifications and equivalents coming within the spirit and terms of the claims appended hereto. 
         [0012]    Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments. 
         [0013]    It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIGS. 1 and 2  are exemplary perspective views of a register cover in accordance with aspects of the present invention and a conventional register in which the register cover may be secured over. 
           [0015]      FIG. 3  is an exemplary perspective view of a rear surface of the register cover in accordance with aspects of the present invention. 
           [0016]      FIG. 4  is an exemplary side profile view of a register cover secured over a register in accordance with aspects of the present invention. 
           [0017]      FIG. 5  is an exemplary rear surface plan view of the register cover in accordance with aspects of the present invention. 
           [0018]      FIG. 6  is an exemplary side profile view of a register cover in accordance with aspects of the present invention. 
           [0019]      FIG. 7  is an exemplary perspective view of a cap enclosure in accordance with aspects of the present invention. 
           [0020]      FIG. 8  is an exemplary cross-sectional perspective view of a fastening member in accordance with aspects of the present invention. 
           [0021]      FIG. 9  is an exemplary flow diagram in accordance with aspects of the present invention. 
           [0022]      FIG. 10  is an exemplary perspective view of a register cover in accordance with aspects of the present invention and metal mounting elements placed on a conventional non-metallic register in accordance with aspects of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
       [0023]    The present invention will now be described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. 
         [0024]    Referring to  FIG. 1 , a conventional register  10  for a heating, ventilation &amp; air conditioning (HVAC) system is disclosed. The conventional register  10  illustrated in  FIG. 1  is a ceiling register. In addition to ceiling registers, one of ordinary skill in the art will readily appreciate that the present invention may be used in connection with all types of registers (e.g., wall registers, louvered registers, patterned registers, etc.). 
         [0025]    As shown in  FIG. 1 , the conventional register  10  includes face  12  having a plurality of openings  14  formed in the face  12  to allow forced air to escape through. The register  10  may further include louvers (not shown) that may be adjusted to control forced air flow through the register. The register  10  may also include sidewalls  16  that extend above a surface (e.g., wallboard, a wall, a ceiling, a finished surface, un-finished surface, etc.) in which the register is attached. The side walls  16  generally will extend above the finished surfaced generally by a thickness (T) of the face. 
         [0026]    As indicated by the arrows in  FIG. 1 , the register cover  20  in accordance with aspects of the present invention is configured to be placed over the register  10 , including the sidewalls  16 .  FIG. 2  illustrates the register cover secured to the register in accordance with aspects of the present invention in order to substantially prevent forced air from exiting through the register  10  or air from entering the register  10 . 
         [0027]    Referring to  FIGS. 1 and 2 , the exemplary register cover  20  in accordance with aspects of the present invention is disclosed. The register cover  20  is configured to be placed over a register to substantially block the flow of air from entering or leaving the register (e.g., register  10 ). The register cover  20  includes a base member  22 , a side wall  24 , and a plurality of securing elements  26  (shown in  FIG. 3 ). 
         [0028]    The base member  22  may be any desirable size or shape. Generally, the base member will be of sufficient size to enclose the register to which it is to be secured to. In one embodiment, base member  22  is sized to cover the entire register  10 , including any sidewalls. The base member  22  is impervious to air, so that air forced through HVAC system will not escape through the base member covering the register  10 . The base member  22  may be any desirable thickness. For example, the base member may have a thickness of about ⅛ inch to about ½ inch. One of ordinary skill in the art will appreciate that the dimensions disclosed herein are exemplary in nature and should not limit the scope of the appended claims. 
         [0029]    As shown in  FIGS. 1 and 2 , the base member  22  includes a front surface  28  and an opposing back surface  30  (shown in  FIG. 3 ). The front surface  28  may be planar or non-planar. In addition, the front surface  28  also may include a decorative pattern or other decorative feature (e.g., color, pattern, texture, etc.) to make the register cover  20  aesthetically pleasing. 
         [0030]    As shown in  FIG. 3 , the back surface  30  may include one or more stiffener ribs  32 . The stiffener ribs  32  may be any desired form. As shown in  FIG. 3 , the stiffener ribs  32  form a square or rectangular grid extending from the back surface  30 . The stiffener ribs  32  may enhance the structural integrity of the register cover and/or provide additional support to the register cover, which may prevent warping or flexing of the front face  28  portion of the base member  22 . The illustrated stiffening ribs have a thickness of about 0.044 inches and are spaced apart about 2.206 inches, for example. One of ordinary skill in the art will readily appreciate that the stiffener ribs are optional features. 
         [0031]    The base member  22  may be made from any desirable material. For example, the base member  22  may be manufactured from an acrylonitrile-butadiene-styrene (ABS) material, a polyvinyl chloride (PVC) material, or any other suitable material. It may be desirable to select a material that includes superior insulative properties. Generally, it is undesirable to use a metal alloy to form the base member unless additional steps are taken to sufficiently insulate the material. 
         [0032]    The base member  22  includes one or more side walls  24  that extend from the base member along a perimeter of the base member. The one or more side walls  24  and the back surface  30  form a cavity (C) for receiving an associated register (e.g. register  10 ). The cavity (C) completely covers the associated register including any register sidewalls that may extend from the wallboard, ceiling and/or other finished or un-finished surface, as shown in  FIG. 2 . 
         [0033]    The one or more side walls  24  may be integrally formed with the base member  22 . For example, the base member and the one or more side walls may be formed during an injection molding process as integral members. Alternatively, the side wall  24  may include one or more side wall members that are secured to the base member  22  by a suitable securing mechanism, such as an adhesive, epoxy, fasteners (e.g., screws, nails, rivets, etc.), etc. 
         [0034]    In one embodiment, the one or more side walls  24  may include a free end  34  that is tapered inward toward the cavity (C), such that the free end may fit tightly against the register  10  and the surface to prevent forced air from escaping the interface formed between the side walls  24  and the register  10 . It may also be desirable to include an insulating member  38  (e.g. a gasket, insulation, a liner or other insulative element) that is attached along the free ends  34  of the side walls to prevent air from escaping the interface formed between the back surface  30 , side walls  24  and the register  10 , as shown in  FIGS. 4 and 5 . The sealing member  38  may be conformable to engage the side walls  24  and the surface surrounding the register. 
         [0035]    In another embodiment, illustrated in  FIG. 6 , it may be desirable to have insulating member  38  secured along the back surface  30  and/or along an interior portion of the side walls  24  (e.g., within the cavity (C)). One of ordinary skill in the art will appreciate that the embodiments disclosed in  FIGS. 4 ,  5  and  6  may be combined such that the cover  20  has insulating members  38  along the free ends  34  of the side walls, as well as along the back surface  30  and/or along an interior portion of the side walls. 
         [0036]    Referring back to  FIG. 3 , a plurality of securing elements  26  are configured along the back surface  30  of the base member  22  to secure the base member to the associated register  20 . This embodiment assumes that the associated register  20  is made of a material that has magnetic permeability suitable to attract the material to the magnet. A method is discussed below for retrofitting a non-metallic register to use with the register cover  20 . 
         [0037]    In the preferred embodiment, the securing elements  26  are magnets. Any type of magnet that is sufficient to secure the register cover  20  to the register  10  may be used in accordance with the present invention. Suitable magnets include, for example, common earth magnets, bar magnets, ring magnets, etc. As shown in  FIG. 3 , a plurality of magnets are used to secure the register cover to the register. It may be desirable to have more or fewer magnets depending on the size of the register  10 , location of the register and/or any other design considerations. 
         [0038]    As shown in  FIG. 3 , the securing elements  26  may be placed in predetermined locations around the back surface  30  of the register cover  20 . The embodiment illustrated in  FIG. 3  shows that there are four (4) fastening members  40  located in each corner of the register. One of ordinary skill in the art will readily appreciate that the fastening members  40  may be positioned in any desired location that will enable the securing elements  26  to sufficiently engage the register  10  so as to secure the register cover  20  to the register  10 . 
         [0039]    As shown in  FIG. 3 , the fastening members  40  may be integrally formed in the back surface  30  of the base member  22 . For example, the fastening members  40  may be formed during injection molding of the cover  20 . 
         [0040]    In another embodiment, the fastening members may be separately attached to the back surface  30  of the base member. Any suitable attachment technique may be used to attach the fastening member  40  to the back surface  30  and/or side walls  24  of the register cover  20 . For example, adhesives, screws, nails, rivets, suction cups, etc. may be used to secure the fastening members  40  to the register cover  20 . Such an embodiment provides flexibility to attach the register cover  20  to a variety of register designs. 
         [0041]    As shown in  FIG. 7 , the securing elements  26  may be housed in a cap  50 , which may be secured to the fastening member  40 . The cap  50  is suitably sized to hold the securing element  26 . In one embodiment, each cap is configured to hold one securing element. As shown in  FIG. 7 , the cap  50  is configured to hold a single cylinder magnet. The cap  50  has opposing walls  52  to hold the securing element  26 . The cap  50  is removably secured to the fastening member  40  located on the back surface  30  of the base member  22 . The cap  50  includes a locking member  54  that interfaces with a groove  62  ( FIG. 8 ) located on the fastening member  40  to secure the securing element  26  within the fastening member  40  and the cover  20 , as shown in  FIG. 7 . One of ordinary skill in the art will readily appreciate that the cap member  50  may take different forms, depending on a variety of design considerations. Such design considerations include, for example, the type of securing element, the type of register that the register cover  20  is to be applied, the size and shape of the register that the register cover  20  is to be applied. 
         [0042]    Referring to  FIG. 8 , a cross-sectional view of an exemplary fastening member  40  is illustrated. The illustrated fastening member  40  is integrally formed in the base member  22  and extends from the back surface  30  into the cavity (C). Referring to  FIG. 7 , the cap  50  includes opposing slots (S) formed between walls  52 . The opposing slots are aligned with guides  60  in order to insert the cap  50  into the fastening member  40 . When the cap  50  including the securing element  26  is inserted into the fastening member  40 , the locking member  54  engages a groove  62  to lock the cap  50  and securing element  26  into the fastening element. The guide  60  further includes an end  64  that acts as a stop to position the securing element  26  (e.g., a magnet) in a desired position. Such a structure provides simple mechanism to lock the cap  50  into fastening member  40  in such a manner to position the securing element (e.g. the magnet) in a suitable position for securing the register cover to the register. 
         [0043]    Referring to  FIG. 8 , the distance (D) between the fastening member  40  and the free end  34  of the side walls  24  should be sufficient to allow the entire register  10  to fit within the cover such that the free end  34  of the sidewalls rests substantially against the surface (e.g., wallboard, a wall, a ceiling, a finished surface, un-finished surface, etc.) in which the register is located. 
         [0044]    As described above, the register cover  20  attaches in seconds to metal registers through the use of magnet securing elements, for example. When the register cover  20  is placed over a register, the side walls  24  come in contact with the surface that surrounds the register. The register cover  20  forms a tight seal over the register between the register cover and the surface surrounding the register, which eliminates the transfer of air from leaving and/or entering the register. 
         [0045]    Aspects of the present invention further relate to a method for attaching a magnetic register cover to a non-metallic register. Referring to  FIG. 9 , the method  70  includes, at block  72  by providing a register cover  20 , wherein the register cover includes a base member  22  impervious to air. The base member includes a front surface  28  and a back surface  30 ; a side wall  24  extending from the base member along a perimeter of the base member, wherein the side wall and the back surface form a cavity (C) for receiving an associated non-metallic register  80  ( FIG. 10 ) and the cavity (C) completely covers the associated non-metallic register; and a plurality of a magnets  26  configured along the back surface to secure the base member to the associated non-metallic register. 
         [0046]    At block  74 , one or more metallic mounts  82  are attached to the associated non-metallic register  80 . The mounts are positioned in such a manner to correspond generally the positions of the magnetic securing elements  26 , such that the one or more metallic mounts  82  are configured to magnetically engage the magnets  26  of the register cover. The metallic mounts  82  may be secured to the non-metallic register  80  in any desired manner. For example, metallic mounts  82  may be secured to the associated non-metallic register through an adhesive, hook and loop fasteners (e.g,.Velcro®), screws, nails, rivets, etc. 
         [0047]    At block  76 , the register cover  20  is placed over the associated non-metallic register  80  to engage the magnets  26  with the metallic mounts  82 . The magnets  26  disposed in the register cover  20  secure the register cover  20  to the one or more metallic mounts  82  and creates an interface between the sidewall  24  and back surface  30  of the register cover  20  and the associated non-metallic register  80  such that forced air is substantially prevented from escaping through the interface. 
         [0048]    While the present invention is described herein in detail in relation to one or more embodiments, it is to be understood that this disclosure is illustrative and exemplary of the present invention, and is made merely for the purposes of providing a full and enabling disclosure of the present invention. The detailed disclosure herein of one or more embodiments is not intended, nor is to be construed to limit the scope of patent protection afforded the present invention, which scope is to be defined by the claims and the equivalents thereof. It is not intended that the scope of patent protection afforded the present invention be defined by reading into any claim a limitation found herein that does not explicitly appear in the claim itself. Thus, for example, any sequence(s) and/or temporal order of steps of various processes or methods that are described herein are illustrative and not restrictive. 
         [0049]    Although the invention has been shown and described with respect to certain embodiments, it is understood that equivalents and modifications will occur to others skilled in the art upon the reading and understanding of the specification. The present invention includes all such equivalents and modifications, and is limited only by the scope of the following claims.

Technology Category: 2