System and Method for HVAC Register Filtration

Abstract

A register filtration system, for use with an HVAC system, includes a top cover, with a plurality of cover slats defining a plurality of cover vent openings. The register filtration system further includes a slider piece, which is slidably arranged with respect to the top cover and includes a plurality of slider slats defining a plurality of slider vent openings. The register filtration system also includes a filter, which is configured for allowing air flow in at least one direction therethrough while capturing debris in an opposite direction. The register filtration system also includes a frame, which is configured for supporting the top cover, slider piece, and filter thereon and for covering a register box opening attached to the HVAC system.

Description

FIELD OF THE INVENTION

The present invention relates to heating, ventilation, and air conditioning (HVAC) systems and, more particularly, to filtration systems for use at register openings for HVAC systems.

BACKGROUND OF THE INVENTION

While a variety of register covers are currently on the market for use in residential and commercial settings, a persistent problem exists in that these register covers do not prevent the falling of trash and debris through the vent openings and into the HVAC system. While duct cleaning services are available, such duct cleaning may not be effective in cleaning out heavier debris that can accumulate during original home construction or remodel, or even during everyday living, especially from household pets. Furthermore, as air is recirculated through the HVAC system, household air is further contaminated by the fallen debris and normal pollutants, thus potentially contributing to health issues for the occupants.

SUMMARY OF THE INVENTION

In accordance with the embodiments described herein, there is provided a register filtration system, for use with an HVAC system, including a top cover, with a plurality of cover slats defining a plurality of cover vent openings. The register filtration system further includes a slider piece, which is slidably arranged with respect to the top cover and includes a plurality of slider slats defining a plurality of slider vent openings. The vent slats have been angled at an approximately 45-degree angle to help push the air out and up into the space to be conditioned. The register filtration system also includes a filter, which is configured for allowing air flow in at least one direction therethrough while capturing debris in an opposite direction. The register filtration system also includes a frame, which is configured for supporting the top cover, slider piece, and filter thereon and for covering a register box opening attached to the HVAC system. In an embodiment, the filter is removably installed within the frame. The filter is formed of at least one of a wire mesh, a plastic mesh, a nylon mesh, a fabric, a mesh made of wood pulse materials, and a mesh material impregnated with a filtration material, such as charcoal-impregnated bamboo mesh and a bamboo charcoal mesh.

In another embodiment, the slider piece is slidable between a first position and a second position such that, when the slider piece is in the first position, the plurality of slide vent openings are substantially unobstructed by the slider piece, and when the slider piece is in the second position, the plurality of slider vent openings are blocked by the slider piece. The slider piece can include a toggle switch to move the slider piece from the first position to the second position.

In still another embodiment, the register filtration system includes a sticker for adhering the filter to the frame. The frame can be formed of a deformable material for accommodating register box frames of various sizes. The registration filtration system can also include a scent sachet and/or an activated charcoal filter, in accordance with an embodiment.

In yet another embodiment, a method for filtering air output from an HVAC system includes providing a register configured for fitting into a register box opening for the HVAC system, wherein the register is further configured for supporting a filter for allowing air flow in at least one direction therethrough while capturing debris in an opposite direction. The method includes providing a scent sachet and/or an activated charcoal filter, in a further embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 show an assembled register cover assembly, in elevation and without the filter insert, to illustrate the hardware configuration to be installed at the register box of an HVAC system, in accordance with an embodiment.

FIG. 3 shows an exploded view of a filtration system, in elevation, illustrating the individual components of the filtration system including a filter insert, in accordance with an embodiment.

FIG. 4 shows a top view of an assembled filtration system, illustrating an exemplary configuration of vent openings, in accordance with an embodiment.

FIG. 5 shows a bottom view of an assembled filtration system, in accordance with an embodiment.

FIG. 6 shows an exploded, front view of a filtration system, in accordance with an embodiment.

FIG. 7 shows a filter insert, in elevation, for use with the filtration system, in accordance with an embodiment.

FIG. 8 shows a bottom view of a filter insert for use with the filtration system, in accordance with an embodiment.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention is described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, the size and relative sizes of layers and regions may be exaggerated for clarity. This invention is adaptable for use in all sizes acceptable by current HVAC standards as well as custom dimensions. Like numbers refer to like elements throughout.

It will be understood that, although the terms first, second, third etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the present invention.

Spatially relative terms, such as “beneath,” “below,” “lower,” “under,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” or “under” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary terms “below” and “under” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. In addition, it will also be understood that when a layer is referred to as being “between” two layers, it can be the only layer between the two layers, or one or more intervening layers may also be present.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items, and may be abbreviated as “/”.

It will be understood that when an element or layer is referred to as being “on,” “connected to,” “coupled to,” or “adjacent to” another element or layer, it can be directly on, connected, coupled, or adjacent to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly connected to,” “directly coupled to,” or “immediately adjacent to” another element or layer, there are no intervening elements or layers present. Likewise, when light is received or provided “from” one element, it can be received or provided directly from that element or from an intervening element. On the other hand, when light is received or provided “directly from” one element, there are no intervening elements present.

Embodiments of the invention are described herein with reference to cross-section illustrations that are schematic illustrations of idealized embodiments (and intermediate structures) of the invention. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments of the invention should not be construed as limited to the particular shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. Accordingly, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the actual shape of a region of a device and are not intended to limit the scope of the invention.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and/or the present specification and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

The present invention seeks to solve the problems described in the Background by providing a filtration system suitable for installation at a HVAC register box opening. An exemplary embodiment of a register cover assembly is shown in FIGS. 1 and 2, with a front elevation view of the assembly shown in FIG. 1 and a bottom elevation view of the assembly shown in FIG. 2. Register cover assembly 100 includes a top cover 102, with a plurality of vent openings 103 defined by a plurality of slats 105. Top cover 102 also includes a flange 108, which removably positions top cover 102 within register cover assembly 100.

Still referring to FIGS. 1 and 2, register cover assembly 100 also includes a slider piece 110, which is slidably attached to top cover 102. Slider piece 110 includes a plurality of vent openings 113 defined a plurality of slats 115. When slider piece 110 is in an “Open” position, vent openings 113 of slider piece 110 align with vent openings 103 of top cover 102 to let air through both top cover 102 and slider piece 110. When slider piece 110 is in a “Closed” position, slats 115 of slider piece 110 align with vent openings 103 of top cover 102 so as to block air flow through top cover 102 and slider piece 110. Open and Closed positions of slider piece 110 may be selected by toggling a slider switch 116 on slider piece 110, which is accessible through top cover 102 via a slider switch opening 117 therein. In the embodiment shown, slider piece 110 is slidably supported against top cover 102 by a plurality of notches 118, as is visible in FIG. 2. Other support structure configurations, such as longer protrusions or groove arrangements, are also contemplated and are considered to fall within the scope of the present disclosure.

As is visible in FIGS. 1 and 2 as well as in subsequent figures, slats 105 of top cover 102 and slats 115 of slider piece 110 are angled at approximately 45 degrees with respect to the plane defined by the top surface of top cover 102. The angled orientation of slats 105 and 115 with respect to the plane of top cover 102, as well as the V-shape arrangement of the openings help to direct the air out and up into the living space.

Continuing to refer to FIGS. 1 and 2, register cover assembly 100 further includes a frame 120, which is configured for insertion into an existing HVAC register box opening (not shown) while supporting top cover 102 and slider piece 110. Frame 120 is designed to flex slightly, especially in the long dimension, so as to be insertable into register box openings of various sizes and shape irregularities. Top cover 102, slider piece 110, and frame 120 may be formed, for example, by injection molding, extrusion molding, or 3D printing using consumer-safe plastic materials. Other materials, such as various types of natural and treated wood, as well as functional and decorative metals, may also be used. In the illustrated embodiment, frame 120 further includes a support strip 122, and side panels 124, including corner pieces 126, for helping to support a filter (not shown in FIGS. 1 and 2) when the filter is inserted into register cover assembly 100, as will be discussed in more detail hereinafter.

FIG. 3 shows an exploded view, in elevation, of a register filtration system including a filter, in accordance with an embodiment. A register filtration system 300 includes top cover 102, slider piece 110, and frame 120 of register cover assembly 100, as previously discussed. Furthermore, register filtration system 300 includes a filter 310, which is configured to fit within frame 120 so as to filter air transmitted through register filtration system 300, while also catching any debris that falls through vent openings 103 and 113 and into register filtration system 300.

FIG. 4 shows a front, exploded view of register filtration system 300, shown here to better illustrate the dimensional relationships between the various components. In an embodiment, filter 310 may be configured to fit within frame 120, then secured in place against frame 120 by flange 108 of top cover 102, when top cover 102 is inserted into frame 120. Alternatively, filter 310 may be cut to be shorter than the full height of frame 124 such that flange 108 does not overlap with filter 310.

Further details of filter 310, in accordance with an embodiment, are shown in FIGS. 5 and 6. FIG. 5 shows a front view, in elevation, of filter 310. Filter 310 as shown includes filter sides 510 connected by a filter bottom 520. Optionally, filter sides 510 may be eliminated and filter 310 may include just filter bottom 520 (i.e., a single flat piece of material). Filter 310 may be formed of, for example, a mesh material that allows air flow therethrough while catching debris larger than a millimeter in diameter. Specific materials used for filter 310 can be selected for specific applications, such as for filtration of debris in the range of sub-micron to one centimeter in size or more, as well as for the desired amount of air flow to satisfy local building requirements (e.g., 350 to 400 cubic feet per minute for air conditioning systems in many municipalities). Possible materials include wire mesh, plastic mesh, nylon mesh, fabric filters, mesh made of wood pulp materials, mesh materials impregnated with filtration materials, such as charcoal-impregnated bamboo mesh or bamboo charcoal mesh. Suitable materials should capture debris falling into register filtration system 300, while still allowing sufficient airflow out from the HVAC system at a sufficient airflow rate to comply with building code regulations.

Referring to FIG. 6 in particular, a bottom view of filter 310 is shown, in accordance with an embodiment. As shown in FIG. 6, bottom 520 of filter 310 includes a support strip sticker 622 and corner stickers 624, which correspond to the shape and locations of support strip 122 and corner pieces 126 of frame 120. Optionally, additional sticker strips may be used on sides 510 of filter 310 to secure filter 310 to, for example, side panel 124 or frame 120 itself. Moreover, additional filtration, air freshening, or fragrance packets may be incorporated within or attached to filter 310. For example, an activated charcoal filter or a scent sachet may be attached to filter 310 or side panel 124 to provide additional air cleansing or fragrance to air pushed through register filtration system 300. Other configurations of filter support structures and structures to secure the filter within register filtration system 300 are contemplated and are considered to be within the scope of the present disclosure.

FIG. 7 shows further details of the assembled register filtration system. As seen from the top, register filtration system 300 includes vent openings 103 that are arranged in a symmetric angled fashion about a center divider 710 in a V-shape arrangement. Assuming register filtration system 300 is installed on a floor with slider switch 116 toward a wall, the angles of slats 105, and thus vent openings 103, are arranged such that air flowing through top cover 102 are pushed away from the wall and into the room in which the register is located. Also, as previously discussed with respect to FIGS. 1 and 2, slats 105 of top cover 102 and slats 115 of slider piece 110 are angled at approximately 45 degrees with respect to the plane defined by the top surface of top cover 102. The V-shape arrangement of the openings, in combination of the angled orientation of slats 105 and 115 with respect to the plane of top cover 102, help to direct the forced air away from the wall and toward the living space. Other designs for the slats and vent openings are contemplated, including those including decorative filigree and ornamental designs, as well as other arrangements of angled slats for directing the air in specific ways.

FIG. 8 shows a bottom view of the assembled register filtration system, illustrating an exemplary way in which filter bottom 520 covers the bottom opening of frame 120. Support strip sticker 622 and corner stickers 624 are aligned with and attach to support strip 122 and corner pieces 126 of frame 120, so as to secure filter 310 to frame 120.

The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. For example, as discussed above, the top cover, slider piece, frame, and filter may be formed of a variety of materials and configurations, as long as the register box opening is covered by the filter so as to allow air to flow outward from the HVAC system as well as to catch debris larger than a predetermined size. A key aspect of the system is that air flow through the register is within the building code guidelines for the location of the system, while preventing sizable debris from falling into the HVAC duct system. The size of the debris to be filtered, as well as the amount of air flow allowed through the register filtration system may be adjusted by the selection of the appropriate filter mesh material and mesh size.

Additionally, the specific dimensions of register filtration system 300 are modifiable to fit any standard register box opening sizes, as well as tailored to custom register box openings.

As still another alternative, just frame 120 and filter 310, without top cover 102 and slider piece 110, may be installed at register boxes during, for example, new construction or renovation of a house or room. Such use would prevent construction debris, such as drywall dust, wood shavings, and carpet fiber, from getting into the existing duct system during construction activity, while protecting the opening of the register box.

Moreover, while the present embodiments have been described as being useful as a register box insert, the same concept may be applied to an HVAC system intake opening in order to filter the air going into the HVAC system, rather than just at the outflow.

Furthermore, while the present embodiments have been described within the context of an HVAC system, the register filtration system may be adapted to fit into other air systems, such as automotive, train, and airplane air conditioning systems, or stand-alone air conditioners and swamp cooler systems.

Accordingly, many different embodiments stem from the above description and the drawings. It will be understood that it would be unduly repetitious and obfuscating to literally describe and illustrate every combination and subcombination of these embodiments. As such, the present specification, including the drawings, shall be construed to constitute a complete written description of all combinations and subcombinations of the embodiments described herein, and of the manner and process of making and using them, and shall support claims to any such combination or subcombination.

In the specification, there have been disclosed embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. Therefore, it is to be understood that the foregoing is illustrative of the present invention and is not to be construed as limited to the specific embodiments disclosed, and that modifications to the disclosed embodiments, as well as other embodiments, are intended to be included within the scope of the appended claims. The invention is defined by the following claims, with equivalents of the claims to be included therein.

Claims

1. A register filtration system for use with an HVAC system, the register filtration system comprising:

a top cover, including a plurality of cover slats defining a plurality of cover vent openings;

a slider piece slidably arranged with respect to the top cover, the slider piece including a plurality of slider slats defining a plurality of slider vent openings;

a filter configured for allowing air flow in at least one direction therethrough while capturing debris in an opposite direction; and

a frame configured for supporting the top cover, slider piece, and filter thereon, and for covering a register box opening attached to the HVAC system.

2. The register filtration system of claim 1, wherein the slider piece is slidable between a first position and a second position such that,

when the slider piece is in the first position, the plurality of slider vent openings are substantially unobstructed by the slider piece, and

when slider piece is in the second position, the plurality of slider vent openings are blocked by the slider piece.

3. The register filtration system of claim 2, wherein the slider piece includes a toggle switch to move the slider piece from the first position to the second position.

4. The register filtration system of claim 1, wherein the filter is further configured to be removably installed within the frame.

5. The register filtration system of claim 1, wherein the filter is formed of at least one of a wire mesh, a plastic mesh, a nylon mesh, a fabric, a mesh made of wood pulp materials, and a mesh material impregnated with a filtration material.

6. The register filtration system of claim 5, wherein the filtration material includes at least one of a charcoal-impregnated bamboo mesh and a bamboo charcoal mesh.

7. The register filtration system of claim 1 further comprising at least one sticker for adhering the filter to the frame.

8. The register filtration system of claim 1, wherein the frame is formed of a deformable material.

9. The register filtration system of claim 1 further comprising a scent sachet for imparting a scent to air flowing through the register filtration system.

10. The register filtration system of claim 1 further comprising an activated charcoal filter.

11. A method for filtering air output from an HVAC system, the method comprising:

providing a register configured for fitting into a register box opening for the HVAC system,

wherein the register is further configured for supporting a filter for allowing air flow in at least one direction therethrough while capturing debris in an opposite direction.

12. The method of claim 11 further comprising providing a scent sachet attachable to the register and configured for imparting a scent to air flowing through the register.

13. The method of claim 11 further comprising providing an activated charcoal filter for additional filtration effects.