DUCT COVER

Abstract

A temporary duct cover for use in an HVAC installation processes. The temporary duct cover having a filtration portion and a closure member. The filtration portion being made from material which is air and water permeable. The closure member being configured to conform a duct. The temporary duct cover minimizes particulate infiltration to the duct while allowing moisture to escape from the duct, thereby inhibiting mold or mildew from forming in the duct.

Description

FIELD OF THE INVENTION

The present invention is directed to duct covers. More specifically, the present invention is directed to protective duct covers which reduces the amount of contaminates that enter duct work during construction and the like, while allowing trapped moisture to escape from the ducts to reduce the likelihood of mold or mildew growth in the ducts.

BACKGROUND OF THE INVENTION

Air handling units and controls for heating, ventilation and air conditioning (HVAC) are expensive and sensitive to outside contaminants, such as, but not limited to, dirt, dust and other debris. Neglecting to cover ducts and equipment during the installation process of an HVAC system can result in a contaminated system that requires cleaning or possible water damage that requires replacement.

During construction of a structure or the like, the ductwork is usually installed after the building is framed, but not yet completed. Therefore, the ducts are usually installed long before the HVAC unit itself is installed and connected. Consequently, in order to avoid contaminants accumulating in the ducts, it is useful to cover the ends of the ducts to inhibit the entrance of the contaminants.

To keep debris, rain or any other contaminants from the ducts which protrude through a roof installation, poly plastic sheeting is often placed on the duct openings and secured with duct tape. Poly plastic is also commonly duct taped around duct openings in the interior of buildings. This process is cumbersome, time-consuming and often requires two people.

Other types of coverings are known, such as described in U.S. Pat. No. 6,874,541, which discloses a temporary duct cover. The duct cover includes a cover envelop having a body, the body having an open end and an opposed closed end with a center portion extending between the open end and the closed end to define an envelope enclosure, the body being made of suitable particle-proof and waterproof material, such as poly plastic, and an elastic member being operably coupled to the body open end and having a relaxed disposition, an expanded disposition, and a duct conforming disposition in compressive sealing engagement with the duct exterior margin.

As described, plastic is used to create a waterproof barrier that prevents airborne contaminants, moisture, and water from entering into the system. However, plastic also prohibits trapped moisture and water from escaping, which can result in the growth of mold or mildew.

It would, therefore, be beneficial to provide duct cover which eliminates the problems with the prior art, and which provides a temporary breathable duct and equipment cover for use during the rough-in stage of an HVAC system. The product inhibits dust and debris from entering the open duct during construction. It will also allow for the transfer of air in order to allow moisture to escape and to reduce the occurrence of mold and/or mildew. Consumers will appreciate the efficiency that this product affords.

SUMMARY OF THE INVENTION

In one embodiment of the invention, the duct cover provides a temporary breathable duct and equipment cover for use during the rough-in stage of an HVAC system.

In another embodiment of the invention, the duct cover inhibits dust and debris from entering the open duct during construction while allowing for the transfer of air in order to allow moisture to escape and to reduce the occurrence of mold and/or mildew.

An embodiment is directed to a temporary duct cover for use in an HVAC installation processes. The temporary duct cover having a filtration portion and a closure member. The filtration portion being made from material which is air and water permeable. The closure member being configured to conform a duct or equipment. The temporary duct cover minimizes particulate infiltration to the duct while allowing moisture to escape from the duct, thereby reducing the likelihood of mold from forming in the duct.

An embodiment is directed to a duct cover having a filtration portion and a closure member. The filtration portion is made from material which restricts the ingress of particulates into a duct, retards the ingress of moisture into the duct and allows the egress of moisture from the duct to reduce the formation of mold or mildew in the duct. The filtration portion has an open end and a closed end. The closure member, which is configured to conform to the duct, is provided at the open end of the filtration portion.

An embodiment is directed to a duct cover having a filtration portion made from material which inhibits particulates larger than 100 microns from passing through the filtration portion and the temporary duct cover. The material having values of greater than approximately 500 g of breathability and values of less than approximately 20,000 mm of water resistance.

Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary duct over which a cover of the present invention may be disposed;

FIG. 2 is a perspective view of the cover of FIG. 1 which is not disposed on the duct;

FIG. 3 is a side view of the cover disposed on the section of the duct shown in FIG. 1, the cover is shown to be transparent to allow the end of the duct to be shown;

FIG. 4 is a perspective view of a first alternate exemplary embodiment of a cover; and

FIG. 5 is a perspective view of a second alternate exemplary embodiment of a cover.

DETAILED DESCRIPTION OF THE INVENTION

An exemplary embodiment of the present invention is a cover 10 made of a suitable material to inhibit dust, debris, and/or other materials from entering ducts 12 or other equipment, such as, but not limited to ducts or equipment relating to HVAC systems. The cover 10 is configured such that a portion of the cover conforms to the shape of the duct 12 over which it is placed on.

In one exemplary embodiment, the cover is made from a spunbond polypropylene material with a closure member 14, such as, but not limited to an elasticized hem, draw string or hook and loop closure. Alternately, the cover may be made from other materials, such as but not limited to flash spun high-density polyethylene fibers or bilaminate fabric or materials. The type of fabric used will determine the filtration (pour size), water resistance capabilities and the water vapor transmission (breathability) of the cover 10. The cover may be offered in different styles and sizes to accommodate the user's needs and the size of the ducts 12. The ducts 12 may be round or rectangular and range from 4 inches to 20 inches or larger. Examples of sizes for the cover include, but are not limited to: small circular, approximately 6 inches—approximately 14 inches diameter or circumference of approximately 44 inches; medium circular, approximately 14 inches—approximately 26 inches diameter or circumference of approximately 81 inches; large circular, approximately 26 inches—approximately 40 inches diameter or circumference of approximately 125 inches; extra large circular, approximately 40 inches—approximately 54 inches diameter or circumference of approximately 169 inches; 2X large circular, approximately 54 inches—approximately 70 inches diameter or circumference of approximately 220 inches; 3X large circular, approximately 70 inches—approximately 90 inches diameter or circumference of approximately 282 inches; medium oval, approximately 14 inches—approximately 26 inches width by approximately 54 inches—approximately 70 inches length or circumference of approximately 165 inches; and large oval, approximately 26 inches—approximately 40 inches width by approximately 70 inches—approximately 90 inches length or circumference of approximately 218 inches. Other sizes can be made per specification.

As shown in FIGS. 2 and 3, the cover 10 has a closure member 14 and a filtration portion 16. In the exemplary embodiment shown, the filtration portion 16 has a general shape of a hair net with an open end 18 and an opposed closed end 20. A circumferentially extending sidewall 22 extends between the open end 18 and the closed end 20. In the exemplary embodiment, the filtration portion 16 is air and water permeable and is a spun bond polypropylene material. However, other materials such as, but not limited to, flash spun high-density polyethylene fibers or bilaminate fabrics may be used without departing from the scope of the invention. Examples of commercially available material, includes, but is not limited to, OXCO Dura 150 White, OXCO SMS, TYVEK 2461 RV, TYVEK 1460, and TYVEK Metallized, the properties of which are hereby incorporated by reference. Any material used must have the filtration characteristics (pour size), water resistance capabilities and the water vapor transmission capabilities (breathability) required to allow for the desired filtration of the dust, debris, and/or other materials and the desired breathability to allow moisture to escape from the ducts. As the material is water resistant, the material delays water penetration; it does not prevent the water penetration.

In one exemplary embodiment, the filtration portion 16 may be made from material or fabric which inhibits particulates larger than approximately 100 microns from passing through the filtration portion 16 and the cover 10. In a first alternate exemplary embodiment, the filtration portion 16 may be made from material or fabric which inhibits particulates larger than approximately 25 microns from passing through the filtration portion 16 and the cover 10. In a second alternate exemplary embodiment, the filtration portion 16 may be made from material or fabric which inhibits particulates larger than approximately 10 microns from passing through the filtration portion 16 and the cover 10. In a third alternate exemplary embodiment, the filtration portion 16 may be made from material or fabric which inhibits particulates larger than approximately 1 micron from passing through the filtration portion 16 and the cover 10.

As stated above, the filtration portion 16 has water resistant capabilities and water vapor transmission capabilities (breathability). Such water resistant/breathable fabrics resist liquid water passing through, but allow water vapor to pass through. Generally, water resistance is measured by the amount of water, in mm, which can be suspended above the fabric before water seeps through. Breathability or water/moisture vapor transmission rate is measured by the rate at which water vapor passes through, in grams of water vapor per square meter of fabric per 24 hour period (g/m²/d), often abbreviated to just “g”.

In an exemplary embodiment, the material or fabric of the filtration portion 16 has values of greater than approximately 750 mm of water resistance. In another exemplary embodiment, the material or fabric has values of less than approximately 20,000 mm of water resistance. In another exemplary embodiment, the material or fabric has values of less than approximately 15,000 mm of water resistance. In another exemplary embodiment, the material or fabric has values of less than approximately 10,000 mm of water resistance. In another exemplary embodiment, the material or fabric has values of less than approximately 5,000 mm of water resistance. In another exemplary embodiment, the material or fabric has values of less than approximately 1,000 mm of water resistance. In another exemplary embodiment, the material or fabric has values of less than approximately 500 mm of water resistance. In another exemplary embodiment, the material or fabric has values of less than approximately 15,000 mm of water resistance and greater than 2,000 mm of water resistance. In another exemplary embodiment, the material or fabric has values of less than approximately 8,000 mm of water resistance and greater than 3,000 mm of water resistance. However, depending upon the environment in which the cover 10 is used, the values of water resistance may be less meaningful, i.e. in indoor environments in which the cover 10 is not subjected to significant rain or other liquid engagement. Therefore, the values of water resistance may fall outside of these ranges without departing from the scope of the invention.

In an exemplary embodiment, the material or fabric of the filtration portion 16 has values of greater than approximately 500 g of breathability or moisture vapor transmission rate. In another exemplary embodiment, the material or fabric has values of greater than approximately 1,000 g of breathability. In another exemplary embodiment, the material or fabric has values of greater than approximately 5,000 g of breathability. In another exemplary embodiment, the material or fabric has values of greater than approximately 10,000 g of breathability. In another exemplary embodiment, the material or fabric has values of greater than approximately 15,000 g of breathability. In another exemplary embodiment, the material or fabric has values of less than approximately 20,000 g of breathability and greater than 5,000 g of breathability. In another exemplary embodiment, the material or fabric has values of less than approximately 18,000 g of breathability and greater than 10,000 g of breathability. However, the breathability is very dependent upon weather conditions, especially temperature and humidity, and therefore, the breathability of the material or fabric may fall outside of these ranges without departing from the scope of the invention.

The values of water resistance and breathability are optimized based on the environment in which the cover 10 is to be used to: i) retard the ingress of moisture into the duct; ii) allow the egress for moisture from the duct to inhibit the formation of mold or mildew in the duct; iii) while maintaining a cost effective price for the cover 10.

Light transmissivity of the filtration portion 16 is not typically an important feature and accordingly, the filtration portion 16 may be clear or opaque as desired.

As shown in FIGS. 2 and 3, the filtration portion 16 has a length dimension L (FIG. 3) measured from the open end 18 to the closed end 20. The open end 18 has a rough or approximate diameter D1 when the open end 18 is formed in a generally circular shape and is in a first or an unstressed position. The rough or approximate diameter D2 of the center portion between the open end 18 and the closed end 20 is greater than the diameter D1. The diameter D3 of the duct 12 on which the temporary duct cover 10 is to be installed is less than the diameter D2 of the center portion.

The closure member 14 is positioned at the open end 18 of the cover 10. The closure member 14 may be fastened to the closure member 14 in any suitable manner using known techniques, such as, but not limited to, sewing or bonding.

If the closure member 14 is an elasticized hem or the like, as shown in FIGS. 1 through 3, the unstressed diameter D1 of the open end 18 will be less than the diameter D3 of the duct 12. However, the closure member 14 can be elastically expanded or stretched to allow the diameter D1 of the open end 18 to be larger than the diameter D3 of the duct 12, thereby allowing the open end 18 to be inserted over the duct 12. The elastic closure member 14 has sufficient resilience and flexibility to attempt to return toward its unstressed position to tightly conform the open end 18 to the duct 12 on which the cover 10 is installed when the elastic closure member 14 is released from its fully expanded stretched position and is permitted to contract about the duct 12 in a duct confirming disposition, as shown in FIG. 3.

With respect to the exemplary embodiment having an elastic hem, in operation, a user stretches open the elastic closure member 14 and slides the open end 18 over the duct 12. In one exemplary embodiment, insertion may continue until the closed end 20 of the filtration portion 16 is generally snug on the opening of the duct 12. However, when inserted the cover 10 on the duct 12, the insertion of the open end 18 may be stopped at different locations along the duct 12. Therefore, the closed end 20 is not always provided in contact with the end of the duct 12. The elastic closure member 14 is then released and the closure member 14 conforms to the duct 12 in compressive, sealing engagement. The elasticity and the positioning of the open end 18 away from the open end of the duct 12 facilitates keeping the cover 10 in sealing engagement with the duct 12 even should the duct 12 have a slight over pressure with respect to ambient conditions.

If the closure member 14 is a draw string (FIG. 4), hook and loop strips (FIG. 5) or the like, the initial diameter D1 of the open end 18 will be likely be greater than the diameter D3 of the duct 12, thereby allowing the open end 18 to be inserted over the duct 12. The closure member 14 is configured to contract about the duct 12 when manipulated by a user or the like to tightly conform the open end 18 to the duct 12 on which the cover 10 is installed.

With respect to the exemplary embodiment having a draw string, hook and loop strips, in operation, a user slides the open end 18 over the duct 12. In one exemplary embodiment, insertion may continue until the closed end 20 of the filtration portion 16 is generally snug on the opening of the duct 12. However, when inserted the cover 10 on the duct 12, the insertion of the open end 18 may be stopped at different locations along the duct 12. Therefore, the closed end 20 is not always provided in contact with the end of the duct 12. The closure member 14 is then tightened to conform the closure member 14 and the open end 18 to the duct 12 in sealing engagement. The forces associated with tightening the closure member 14 and the positioning of the open end 18 away from the open end of the duct 12 facilitates keeping the cover 10 in sealing engagement with the duct 12 even should the duct 12 have a slight over pressure with respect to ambient conditions.

The duct and/or equipment cover as described herein provides consumers with a breathable cover to inhibit dust and debris from entering open ducts, such as HVAC ducts, and equipment during construction. However, because of the breathability of the filtration portion 16 of the cover, moisture and water vapor may escape from the duct 12 even when the cover 10 is provided in engagement with the duct 12. It is often the case during construction that moisture will accumulate in the newly installed ducts. This is particularly true in areas with high humidity. If waterproof covers are positioned over the openings of the ducts, air flow in the ducts is prevented and the moisture trapped in the ducts stagnates and causes mold. As the current invention described herein is made from breathable material or fabric, moisture initially trapped in the duct can escape, reducing the likelihood of mold or mildew from forming in the duct.

The closure member, whether it is an elasticized hem, draw string, hook and loop fasteners or other type of closure allows for a snug fit around the duct or equipment. These covers are easy and fast to install. The covers may be washed and reused if proper care is exercised. No tapes or adhesives are required. The duct and equipment cover styles all include breathability for water vapor transmission and include dust, debris and water resistance characteristics. These characteristics will vary depending on the type and style of material used. These covers are designed for interior use that are subject to minimal or no precipitation or direct contact with unprotected weather elements.

Alternative embodiments of the cover may include a waterproof center or top in conjunction with the spunbond polypropylene, flash spun high-density polyethylene fibers or bilaminate breathable outer sides which may be used for covering a duct or equipment that is in direct contact with the outdoor elements. The center or top of the cover would prevent water, dust and debris from entering into the covered product. The sides would be water resistant and breathable allowing the water to shed down off the water proof center. This would allow the cover to withstand infiltration of water with the capability of the breathable side material allowing the transfer of air so as not to trap moisture under the protective cover.

While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.

Claims

1. An temporary duct cover for use in an HVAC installation processes, the temporary duct cover comprising:

a filtration portion, the filtration portion made from material which is air and water permeable;

a closure member which is configured to conform to a duct;

wherein the temporary duct cover minimizes particulate infiltration to the duct while allowing moisture to escape from the duct, thereby inhibiting mold or mildew from forming in the duct.

2. The temporary duct cover as recited in claim 1, wherein the filtration portion is made from spunbond polypropylene.

3. The temporary duct cover as recited in claim 1, wherein the filtration portion is made from flash spun high-density polyethylene fibers.

4. The temporary duct cover as recited in claim 1, wherein the filtration portion is made from bilaminate materials.

5. The temporary duct cover as recited in claim 1, wherein the filtration portion is made from fabric which inhibits particulates larger than 100 microns from passing through the filtration portion and the temporary duct cover.

6. The temporary duct cover as recited in claim 5, wherein the fabric inhibits particulates larger the 25 microns from passing through the filtration portion and the temporary duct cover.

7. The temporary duct cover as recited in claim 6, wherein the fabric inhibits particulates larger the 10 microns from passing through the filtration portion and the temporary duct cover.

8. The temporary duct cover as recited in claim 7, wherein the fabric inhibits particulates larger the 1 micron from passing through the filtration portion and the temporary duct cover.

9. The temporary duct cover as recited in claim 1, wherein the closure member is made from elasticized hem.

10. The temporary duct cover as recited in claim 1, wherein the closure member is made from a draw string.

11. The temporary duct cover as recited in claim 1, wherein the closure member is made from a hook and loop closure.

12. The temporary duct cover as recited in claim 1, wherein the filtration portion is made from fabric having values of greater than approximately 500 g of breathability.

13. The temporary duct cover as recited in claim 1, wherein the filtration portion is made from fabric having values of less than approximately 20,000 mm of water resistance.

14. A duct cover comprising:

a filtration portion, the filtration portion made from material which restricts the ingress of particulates into a duct, retards the ingress of moisture into the duct and allows the egress of moisture from the duct to inhibit the formation of mold in the duct, the filtration portion having an open end and a closed end;

a closure member which is configured to conform to the duct, the closure member being provided at the open end of the filtration portion.

15. The duct cover as recited in claim 14, wherein the filtration portion is made from spunbond polypropylene.

16. The duct cover as recited in claim 14, wherein the filtration portion is made from flash spun high-density polyethylene fibers.

17. The duct cover as recited in claim 14, wherein the filtration portion is made from bilaminate materials.

18. The duct cover as recited in claim 16, wherein the closure member is made from an elasticized hem.

19. A duct cover comprising:

a filtration portion, the filtration portion made from material which inhibits particulates larger than 100 microns from passing through the filtration portion and the temporary duct cover, the material having values of greater than approximately 500 g of breathability and values of less than approximately 20,000 mm of water resistance.

20. The duct cover as recited in claim 20, wherein a closure member is provided on the duct cover, the closure member is configured to conform to a duct, the closure member being provided at an open end of the filtration portion.