DRY WALL EXTRUSION GRILLE FRAME WITH SEISMIC TETHER

Abstract

A one piece dry wall extrusion grille frame comprising: a frame; pre-drilled installation holes in said frame; a lip for plastering; grille or register; capture recesses for plaster; the grille or register secured to the frame by a tether(s), cable(s) or wire(s) to ensure that the grille or register does not separate from the frame, and no additional hardware for drop in installation.

Description

RELATED APPLICATIONS

The present invention is a continuation in part of application Ser. No. 15/476,855 filed on Mar. 31, 2017, which is a continuation in part of U.S. patent application Ser. No. 13/999,038 filed Jan. 6, 2014, now U.S. Pat. No. 9,765,988. This application is also a continuation-in-part of application Ser. No. 14/545,029 filed Mar. 18, 2015.

FIELD OF THE INVENTION

The present invention relates to a one piece dry wall extrusion grille frame comprising installation holes, a lip, capture recesses, a projection which provides a surface for the grille to rest upon, and a tether securing the grille panel to the frame. The grille frame mounts flush to the wall.

BACKGROUND OF THE INVENTION

U.S. Pat. No. 5,082,083 relates to a structure wall mounted speaker assembly. The woofer of the speaker is mounted in the assembly wall frame and the tweeter is both mounted in and self-contained within the assembly wall frame. The installation requires only that a circular opening be cut in the wall to enable the rear portion of the woofer to extend through the dry wall or sheetrock and two simple holes drilled in the wall to accommodate the support bolts to retain the wall mounted speaker assembly on the wall.

U.S. Pat. No. 7,140,960 relates to duct systems, registers and ductwork components used with floor or ceiling registers employed in warm air heating, ventilating and air conditioning systems, and improvements for mounting and installing components of the duct system, including register boots, mud rings and register grilles, in the walls, floors or ceilings of buildings components, mud ring, register grille and wall, floor or ceiling opening, which reduces costs.

U.S. Pat. No. 7,771,259 relates to a flush mounted frame for an access panel or register. The frame is mounted to a wall, ceiling or floor surface, and is made by joining linear frame sections each providing interconnected elements formed by an extrusion process. A first planar element is spaced apart from a second planar element and positioned for abutting a common surface. A first channel element is formed between the first and second planar elements. A third planar element is positioned normal to the first and second planar elements and terminates with a rib directed toward the first planar element. When mounted onto studs in a building structure, wall putty or mud may be placed into a space between the wall panels and the third planar element, the mud is captured in place forming a smooth interface between the frame assembly and the surrounding wall surfaces.

The prior art relies on corner keys, locks to create a frame and extra components. The prior art does not have a flexible mounting flange. The prior art requires attachment to a structural member, stud or beam, and therefore a skilled installer is needed to install the prior art grille frame.

The prior art requires multiple planar extensions and complexities requiring more costly material/extrusions. With the prior art, one cannot create a radius or curved frame.

The prior art does not teach a device for securing the grille panel or register to the frame.

SUMMARY OF THE INVENTION

The present invention relates to a one piece dry wall extrusion grille frame. The dry wall extrusion grille frame needs no additional hardware for drop in installation. The dry wall extrusion grille frame comprises pre-drilled installation holes, a lip for plastering, and capture recesses for plaster, a projection which provides a surface for the grille to rest upon, a tether(s) for securing the grille panel to the frame. The grille frame mounts flush to the wall.

It is an object of the present invention for the dry wall extrusion grille frame to comprise a structure constructed of four extrusions welded together to create a strong, single piece frame. It is an object of the present invention for the frame to comprise multiple, pre-punched holes. It is an object of the present invention for the frame to comprise a flexible mounting flange.

It is an object of the present invention for the flexible mounting flange to enable an installer with basic skills to position the frame at a wall, floor, ceiling, duct or ventilation opening.

It is an object of the present invention for the flexible mounting flange to contain multiple recesses to capture mud, plaster, or wallboard compound.

It is an object of the present invention for the grille frame to comprise a projection that is perpendicular to the mounting flange for providing an installer with a natural guide for a wallboard compound, plaster or mud knife to simplify application of plaster, mud or spackle compound.

It is an object of the present invention for the flange to be positioned anywhere along the projection.

It is an object of the present invention for the dry wall extrusion grille frame to not require fixturing or attachment to a structural building element, wall stud or support beam. This eliminates the need for the installer to locate the position and spacing of a structural element, wall stud or support beam, greatly reducing installation time and labor costs and the skill level of an installer.

It is an object of the present invention for the frame to comprise numerous pre-punched holes through which standard securing devices secure the unit to a wall, floor or ceiling. It is an object of the present invention for the securing devices to comprise standard wallboard screws. It is an object of the present invention for the frame to alternatively be attached with construction adhesive or silicone.

It is an object of the present invention for the frame to include a projection that goes into an opening providing stability and a mounting point for a damper or filter.

It is an object of the present invention for the frame to mount flush so that a perforated metal, wood or plastic grille or register attached to the frame is also flush to the wall.

It is an object of the present invention for there to be a projection opposite of the flange to provide support for the perforated metal, plastic, and wood registers and grilles.

It is an object of the present invention to comprise a flange large enough to provide left to right and top to bottom positioning adjustability to an installer, saving time and the need to precision cut the opening.

It is an object of the present invention for the grille frame to further comprise a T shaped extruded projection that provides strength while embodying amounting flange, frame structure, and the ability to customize fastening points.

It is an object of the present invention for the T shaped frame to comprise welded or extruded projections, tabs or ledges for attaching perforated metal, plastic, and wood registers and grilles to the grille frame. This provides total customization for the number and placement of the grille/register mounting screw locations while insuring there is minimal interference with air flow.

It is an object of the present invention that the perforated metal, plastic, and wood registers and grilles are attached to the frame with mechanical fasteners, clips, magnets, pins, studs, snaps or ball catches.

It is an object of the present invention for the frame design to include a projection as part of the extrusion should air flow be a concern.

It is an object of the present invention for the frame to be constructed of four extrusion lengths, which can be cut to any length and welded at the corners to create a strong, one piece structure in a square, rectangular, geometric or radius shape.

It is an object of the present invention for the dry wall extrusion grille frame to comprise a frame, a grille or register, sheet rock screws, pre-perforated through holes, indented slots, a flexible edge and a tether or connecting cable or wire to the frame.

It is an object of the present invention for the indented slots to capture joint compound, mud or plaster.

It is an object of the present invention for the flexible edge to be used for fastening to a wall or ceiling with pre-perforated through holes.

It is an object of the present invention fora common sheet rock or wall board screws to be threaded into the wall material.

It is an object of the present invention for the frame to be installed with standard sheet rock or wallboard screws before plaster or a joint compound is applied.

It is an object of the present invention for the frame to be installed with silicone or construction adhesive in lieu of sheet rock or wall board screws.

It is an object of the present invention for the dry wall extrusion grille frame to be installed to a wall with four sheet rock or wallboard screws.

It is an object of the present invention for the extrusion grille frame to have pre-punched mounting through holes providing many mounting options to address multiple wall, floor or ceiling conditions.

It is an object of the present invention for the extrusion grille frame to be a fully welded construction that provides exceptional strength for mounting in walls, floors and ceilings.

It is an object of the present invention for the frame to be constructed with clips or connectors.

It is an object of the present invention for the extrusion grille frame to have multiple, pre-punched mounting holes for fastening in a wide range of wall and ceiling conditions and materials

It is an object of the present invention for the extrusion grille frame to have pre-punched holes accurately sized for standard wall board/sheet rock screws so no special hardware or tools are required.

It is an object of the present invention for the extrusion grille frame to have multiple indented slots along the mounting flange to provide capture points for joint compound, mud or plaster.

It is an object of the present invention for the extrusion grille frame to comprise flexible mounting flange that fasten the grille to uneven or curved wall surfaces.

It is an object of the present invention to have unlimited shape possibilities for the frame, including but not limited to radius, square, rectangular, angular, round, triangular, concave and convex.

It is an object of the present invention for the inside of the extrusion grille frame to extend a minimum of ⅝″ deep into the opening so that the extrusion grille frame is installed in a wall board or plaster ranging from about ¼″ thru about ¾″ thick.

It is an object of the present invention for the extrusion grille frame to allow an installer to cut a very rough hole or opening in a wall or ceiling and slip the extrusion grille frame into the opening. It is an object of the present invention for there to be no routing or recessed cut that is necessary. It is an object of the present invention for there to be no blocking or added wood supports necessary for attachment to a wall or ceiling.

It is an object of the present invention for the extrusion grille frame to combine the exceptional strength and light weight characteristics of aluminum material—thus enabling safe use in ceiling applications.

It is an object of the present invention for the extrusion grille frame to be mounted, so that the entire frame and grille are flush to the wall providing a seamless installation —which makes field painting much easier—also makes future cleaning of the grille simpler as can be done with simply the wipe of a rag.

It is an object of the present invention for the extrusion grille frame to be mounted in only one way, so that it cannot be installed backward.

It is an object of the present invention that the perforated metal, plastic, and wood registers and grilles be secured or attached to the frame with a tether(s), cable(s) or wire(s).

It is an object of the present invention that the perforated metal, plastic, and wood registers and grilles be secured or attached to the frame with a tether(s), cable(s) or wire(s) to ensure the perforated metal, plastic, and wood registers and grilles do not separate from the frame.

It is an object of the present invention that the perforated metal, plastic, and wood registers and grilles be secured or attached to the frame with a tether(s), cable(s) or wire(s) to ensure the perforated metal, plastic, and wood registers and grilles do not separate from the frame due to fastening mechanisms unthreading, unsnapping or failing during vibration or a seismic event.

It is an object of the present invention that the perforated metal, plastic, and wood registers and grilles be secured or attached to the frame with a tether(s), cable(s) or wire(s) to ensure the perforated metal, plastic, and wood registers and grilles do not separate from the frame due to fastening mechanisms unthreading, unsnapping or failing during vibration or seismic event providing additional safety when mounting in walls or ceilings.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows a view of the frame of the present invention to be welded together.

FIG. 2 shows a view of the frame of the present invention that is welded together.

FIG. 3 shows a view of the frame of the present invention to be welded together.

FIG. 4 shows a view of the frame of the present invention that is welded together.

FIG. 5 is a cross sectional view of the extrusion grille frame of the present invention.

FIG. 6 shows a solid projection of the extrusion grille frame of FIG. 5 as a solid piece.

FIG. 7 shows a welded projection of the extrusion grille frame of FIG. 5 as a welded piece.

FIG. 8 is a front view of an extrusion grille frame of the present invention.

FIG. 9 is a front view of an extrusion grille frame of the present invention.

FIG. 10 is a front view of an extrusion grille frame of the present invention.

FIG. 11 is a cross-sectional view through section A-A of FIG. 10.

FIG. 12 is a cross-sectional view through section B-B of FIG. 10.

FIG. 13 is an enlarged view of section C of FIG. 11.

FIG. 14 is a front view of an extrusion grille frame of the present invention.

FIG. 15 is a cross-sectional view through section A-A of FIG. 14.

FIG. 16 is a cross-sectional view through section B-B of FIG. 14.

FIG. 17 is an enlarged view of section C of FIG. 15.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows the frame 10 comprising four mitered pieces 12, 14, 16 and 18, which are welded at 20, 22, 24, and 26. The frame has a flexible mounting flange 28, and multiple pre-punched holes 30. FIG. 2 shows the frame 10 of FIG. 1 welded together.

FIG. 3 shows the frame 40 comprising four mitered pieces 42, 44, 46 and 48, which are welded at 50, 52, 54, and 56. The frame has flexible mounting flange 58, and multiple pre-punched holes 60. FIG. 4 shows the frame 40 of FIG. 3 welded together.

FIG. 5 shows the grille or register 100, mounted to the dry wall extrusion grille frame which is mudded or plastered, flushed with the wall. The extrusion grille frame further comprises multiple recesses 104 used to capture joint compound, mud or plaster 102, and projections 106 and 110 that provides a projection for a spackle knife to rest on. The projection 106 can be made as one piece as shown in FIG. 6 or be a welded projection 110 as shown in FIG. 7. The projections 120 can be where the grille or register 100 is mounted. As shown in FIG. 5, the projections 120 creates a flush mount for the grille or register 100. The projection 106 projects into an opening shown in FIG. 5. Common sheet rock screw 112 and 114 are threaded into the wall material.

FIGS. 8-10 show the grille frame 140 having multiple pre-punched holes 142, and a large mounting flange 144. The grille frame 140 is flush mounted 146.

FIG. 11 is a cross-sectional view through section A-A of FIG. 10.

FIG. 12 is across-sectional view through section B-B of FIG. 10.

FIG. 13 is an enlarged view of section C of FIG. 11.

FIG. 14 shows a register 160 and a frame 162 having multiple pre-punched holes 164 and a large mounting flange 166. The grille frame 160 is flush mounted 168.

FIG. 15 is a cross-sectional view through section A-A of FIG. 14. A tether 170 is attached to the register 160 and the frame 162 so that the register 160 does not separate from the frame 162.

FIG. 16 is a cross-sectional view through section B-B of FIG. 15. A tether 170 is attached to the register 160 and the frame 162 so that the register 160 does not separate from the frame 162.

FIG. 17 is an enlarged view of section C of FIG. 15. FIG. 17 shows tether 170 attached to frame 162.

Claims

1. A dry wall extrusion grille comprising:

a frame;

a grille or register located in said frame;

indented slots;

through holes;

a flexible mounting flange located between a top and bottom edge of the frame extending outwardly from said frame;

said indented slots defined as small recesses in said flexible mounting flange that receive plaster, joint compound or mud;

wherein said extrusion grille is used with a fixed core, a core welded directly to said frame, or a removable core for access to controls or filtration behind said grille;

said grille or register attached to said frame by a tether(s), cable(s) or wire(s) to ensure that said grille or register does not separate from said frame.

2. The extrusion grille of claim 1 wherein said flexible mounting flange is fastened to a wall or ceiling with said through holes being pre-perforated.

3. The extrusion grille of claim 2 further comprising sheet rock screws.

4. The extrusion grille of claim 1 wherein said frame is constructed of mitered pieces.

5. The extrusion grille of claim 4 wherein said mitered pieces are welded together.

6. The extrusion grille of claim 1 wherein said register or grille is attached to said frame with mechanical fasteners, clips, magnets, pins, studs, snaps or ball catches.

7. The extrusion grille of claim 3 wherein said frame is installed with said sheet rock screws before plaster or a joint compound is applied.

8. The extrusion grille of claim 1 wherein said extrusion grille is a fully welded construction.

9. The extrusion grille of claim 1 wherein an inside of said extrusion grille frame extends about ¾″ deep into an opening so that said extrusion grille is installed in a wall board or plaster ranging from about ¼″ thru about ¾″ thick.

10. The extrusion grille of claim 1 wherein said extrusion grille is mounted, so that said entire frame and grille are flush to a wall providing a seamless installation.

11. A dry wall extrusion grille comprising:

a frame;

a grille or register located in said frame;

through holes located in a flexible mounting flange;

indented slots;

said flexible mounting flange located between a top and bottom edge of the frame extending outwardly from said frame;

said indented slots defined as small recesses in said flexible mounting flange that receive plaster, joint compound or mud;

said grille or register attached to said frame by a tether(s), cable(s) or wire(s) to ensure that said grille or register does not separate from said frame;

said frame being extended to at least ¾″.

12. A dry wall extrusion grille comprising;

a frame;

a grille or register located in said frame;

through holes located in a flexible mounting flange;

indented slots;

said flexible mounting flange located between a top and bottom edge of the frame extending outwardly from said frame;

said indented slots defined as small recesses in said flexible mounting flange that receive plaster, joint compound or mud;

said grille or register attached to said frame by a tether(s), cable(s) or wire(s) to ensure that said grille or register does not separate from said frame;

mounting strips attached to a bottom of said frame.

13. The extrusion grille of claim 12 wherein said mounting strips are attached to said frame via welding.

14. The extrusion grille of claim 12 wherein said mounting strips are made as an integral part of said frame in one piece extrusion.

15. The extrusion grille of claim 12 further comprising an attachment device for attaching said linear bar grille to said frame.

16. The extrusion grille of claim 15 wherein said attachment device includes mechanical fasteners, threaded inserts in said mounting strips to be used with mechanical fasteners, or a projection on the frame or said mounting strips for use with spring steel clips or magnets.

17. The extrusion grille of claim 12 further comprising various style and depth angled edges to capture plaster or joint compound.

18. The extrusion grille of claim 12 further comprising a lip for plastering.