AIR DUCT REGISTER WITH IMPROVED AIR FLOW

Abstract

A register for mounting on an opening of an air duct in a structure includes an annular face plate with a perimeter side wall sized and configured for a close fit with the opening. Two plenums are positioned inside the perimeter side wall, with a recess surrounding the plenums. Each plenum has a planar top surface that is adjacent or nearly co-planar with the annular face plate. The plenums open to the air duct and define a plurality of cavities beneath the top surface. A plurality of vent openings are defined in a perimeter wall of each plenum so that air from the air duct enters the plurality of cavities and flows through the plurality of vent openings and through the recess into the surrounding environment. The register presents a generally uniform aesthetic appearance between the face plate and the top surfaces of the plenums. The configuration of the cavities and vent openings creates turbulent air flow, thereby increasing the air flow through the register relative to louvered registers having the same flow area.

Description

BACKGROUND

There are many different types of registers for air ducts. One common type is simply a face plate that covers an air duct opening in a floor, wall or ceiling. In its simplest form, the face plate consists of a grid or ornamental design with openings for passage of air from the duct into the surrounding environment. In another form, the typical face plate includes a series of louvers with a mechanism to move the louvers to control the direction and volume of air flow through the register. Dampers, filters and humidifiers are sometimes integrated into registers for air ducts.

Registers are typically manufactured from a metal, such as steel or aluminum, and plastic, and are usually rectangular or circular. Most registers for air ducts within floors are manufactured from steel or high-strength plastic. The grid or louvered design of the conventional register is often unsightly and can mar the appearance of home surfaces. It is also unpleasant to tread upon registers installed in a floor. Moreover, the grid or louvered design allows dust, dirt and debris to fall through the register into the air duct, which is difficult to clean.

There is a need for an improved register for air ducts that provides a “clean” appearance while providing optimal air flow and dispersion into the surrounding environment. There is also a need for an improved register that prevents the passage of dirt and debris into the duct on which the register is mounted.

SUMMARY

An air duct register for mounting in an opening of a structure in communication with an air duct includes an annular face plate with a perimeter side wall sized and configured for a close fit with the opening. One or more plenums are positioned inside the perimeter side wall, with a recess surrounding the plenums. Each plenum has a planar top surface that is adjacent or nearly co-planar with the annular face plate.

Each plenums includes an annular wall with a plurality of transverse panels defining a plurality of cavities beneath the top surface of the plenums. A plurality of vent openings are defined in the perimeter wall of each plenum so that air from the air duct enters the plurality of cavities and flows through the plurality of vent openings into the recess. The register presents a generally uniform aesthetic appearance between the face plate and the top surfaces of the plenums. The configuration of the cavities and vent openings creates turbulent air flow, thereby increasing the air flow through the register relative to louvered registers having the same flow. The configuration of the vent openings also prevents dirt and debris from entering the air duct, instead collecting within the recess surrounding the plenums.

In a further feature, the perimeter side wall includes a plurality of resilient clips for engaging the structure, such as a floor, at the opening to the air vent. In addition, a rotating cam locks can be provided at the opposite ends of the register, in which the cam locks are rotated by a screw drive into and out of a locking engagement with the structure or floor.

In another feature, the register includes an annular shroud extending a variable distance from the annular side wall. The annular shroud interferes with the air flow path in the air duct to generate turbulence entering the register, which in turn enhances the air flow through the register.

DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of a register according to the present disclosure mounted on a duct of a ventilation or HVAC system.

FIG. 2 is a top view of the register shown in FIG. 1.

FIG. 3 is a bottom perspective view of the register shown in FIG. 1.

FIG. 4 is a side cross-sectional view taken along line 4-4 in FIG. 2.

FIG. 5 is a cut-away view showing the register of FIG. 1 mounted in a floor duct.

FIG. 6 is an end cross-sectional view taken along line 6-6 in FIG. 5.

DETAILED DESCRIPTION

For the purposes of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the disclosure is thereby intended. It is further understood that the present disclosure includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles disclosed herein as would normally occur to one skilled in the art to which this disclosure pertains

Referring to FIG. 1, a register 10 according to the present disclosure is mounted to the outlet of a duct D. The duct can be a floor duct of a building HVAC system, and particularly a residential HVAC system. However, the register 10 is adapted to be mounted on a wall or ceiling duct. In the illustrated embodiment, the register is sized for a conventional rectangular residential HVAC duct that is 10 inches long by 3.5 inches wide. The register 10 includes an annular face plate 15 in the form of a rectangular perimeter configured to be seated on a surface, such as a floor, in which the duct D is positioned. Referring to FIGS. 2-3, the face plate 15 merges into a downward-extending perimeter side wall 25 that is sized and configured for a close fit within the opening O in the structure bearing the air duct, such as floor F in FIG. 5. The perimeter side wall defines a recess 16 beneath the face plate that extends through the structure F toward the duct D when the face plate is mounted over the opening. The recess 16 houses at one or more, and preferably two, plenums 20, each defining a plurality of vent openings 11 that communicate air from the duct to the surrounding environment. The vent openings 11 are defined in perimeter 18 of the plenums so that the register 10 presents a “clean” appearance, as shown in FIG. 1. Rather than a grid or louvers, the exposed face of the register is defined by the perimeter face plate 15 and by the substantially planar top surfaces 20a of the plenums 20. The planar top surfaces of the plenums are sized to fill the majority of the facing area of the opening O in the structure or floor F. The top surfaces are adjacent the face plate and are preferably planar or nearly planar with the face plate 15. Not only does this configuration prevent seeing through to the duct D below, it also provides smooth surfaces in the event that a person steps on the register.

As shown in FIGS. 2-6, the register includes a bottom wall 17 having a portion that projects inward from the perimeter side wall 25 to engage the perimeter wall 18 of the plenums 20, and a portion that extends between the adjacent plenums, as best seen in FIG. 2. It can be appreciated that the recess 16 essentially surrounds the plenums like a moat between each other and between the plenums and the annular side wall 25 of the register. The plenums are essentially rectangular boxes, with the perimeter wall including an outer side wall 18a, an inner side wall 18b and opposite end walls 18c. The boxes open towards the interior of the duct D and supported within the face plate 15 by the annular side wall 25 and bottom wall 17. A plurality of stiffening ribs 19a extend between the annular side wall 25 and the adjacent outer side wall 18a of the plenums. A plurality of interior stiffening ribs 19b extend between the inner side walls 18b of adjacent plenums, as shown in FIG. 2. A center rib 21 extends along the bottom wall 17 between the adjacent plenums, as best seen in FIG. 6. The ribs 19a, 19b, 21 provide stiffness and support for the plenums 20 inside the face plate 15 so that the plenums can bear some force or weight should a person step on the register.

Looking at the underside of the register 10 shown in FIG. 3, the plenums 20 include a plurality of transverse panels 22 that can merge into stiffening ribs 19a, 19b. The transverse panels 22 extend between the outer side wall 18a and the inner side wall 18b of each plenum to form a plurality of individual cavities 23 within each plenum. In the illustrated embodiment, five transverse panels 22 (with five corresponding ribs 19a, 19b) define six cavities 23 that open into the duct D to receive air flowing through the duct. The register 10 can have a different number of transverse panels, and therefore a different number of cavities; however, more cavities can adversely affect air flow through the register, and significantly fewer transverse panels can compromise the strength of the register. The cavities 23 communicate with the vent openings 11 formed in the perimeter walls 18 of the plenums 20, thereby providing a path for air A to flow from the duct, through the plenums 20, into the recess 16 and out to the environment surrounding the register 10, as depicted in FIG. 6. In one embodiment, the vent openings 11 are rectangular in shape and span the majority of the area of the plenum perimeter wall 18 between the transverse panels 22. In a specific embodiment, the vent openings can be 1.5×1 inch.

As shown in FIG. 6, the air flow A must make a right angle turn to enter the vent openings 11, and then another right angle turn to exit the recess 16 of the register 10. This flow path induces turbulence in the air flow A, which increases the overall air flow through the register into the surrounding environment. Turbulent air flow is also created by the distinct cavities or pockets defined in the plenums 20 as the air flow is forced from the duct D into the pockets. The configuration of the plenums and vent openings in the register 10 provides greater air flow than a conventional louvered register with a comparable flow area. Although a single plenum is possible, the air flow through the vent openings of a single plenum can be fairly limited. Two plenums are preferred, which doubles the number of vent openings and thus the total flow area.

Another benefit of the plenum and vent openings of the present disclosure is that there is no clear “line of sight” into the duct D. This provides an aesthetic benefit since the view of the register 10 is dominated by the face plate 15 and the top surfaces 20a of the plenums. In one specific embodiment, the recess 16 between the plenums and the perimeter side wall 25 and between the two plenums 20 has a width of 0.25-0.5 ins., and the bottom wall 17 sits 1.5-2.5 ins. below the top surface 20a of the plenums. These dimensions limit the view of the vent openings 11 and of the bottom wall, as is apparent in the view of FIG. 1.

Another benefit is that the right angle turn arrangement prevents dust, dirt and debris from entering the duct. Instead, the debris will collect on the bottom wall 17 at the base of the recess 16 between the plenums and between the plenums and the side walls 25 of the register. The narrowness of the recess 16 helps conceal the debris at the bottom of the recess. The register can be removed from the duct opening as needed to clean the register of accumulated dust and debris.

The register 10 can include an inlet shroud 40 projecting downward from the side wall 25 of the register, as shown in FIGS. 5-6. The shroud 40 is sized to project into the duct D by a dimension extending from the perimeter side wall and the underside of the structure F when the register is mounted within the opening O. The shroud projects into the air flow A through the duct, as shown in FIG. 5, which generates turbulence at the entrance to the register plenums. This turbulence enhances the air flow through the register. The extension dimension of the shroud 40 ranges between a minimum dimension I and a maximum dimension M. In one embodiment, the minimum dimension I is 0.125 in. to increase turbulent air flow from the interior of the duct into the plenums 20 of the register. The maximum dimension M is dependent on the size of the duct, and in particular on the depth of the duct at the opening O. In a preferred embodiment, the maximum dimension of the shroud 40 is half (½) the depth of the duct configured as shown in FIG. 5. In certain embodiments, the maximum dimension is 2.0 ins. In some cases, the duct extends downward from the opening, like the duct boot configuration shown in FIG. 1. In this case, the dimension of the shroud 40 is less critical because the air flow through the duct D is not transverse to the register, such as the air flow A shown in FIG. 5.

In one embodiment, the shroud 40 is integrally formed with the side wall 25 of the register. In this embodiment, a variety of registers 10 may be provided with different dimensions of the shroud. A register with a particular shroud dimension can be selected for optimum air flow for a given duct. In an alternative embodiment, the shroud 40 can be adjustably fastened to the side wall 25, such as in a telescoping fashion, to allow manual adjustment of the shroud dimension between the minimum and maximum dimensions I and M.

The register includes a plurality of clips 26 affixed to the side wall 25 of the register, as best seen in FIGS. 3, 5, 6. The free end of the clips define a latch 27 that is configured to engage the underside of the structure, such as floor F, on which the register is mounted. The latch 27 is a resilient arm that flexes inward toward the side wall when the register is pushed into the opening O in the structure F, and then resiliently returns to tis free state when the latch 27 moves below the underside of the structure. In one embodiment, two such clips 26 are provided on each long side of the register adjacent each end. The clips can be integrally formed with the side wall, or can be separately attached in a conventional manner.

The clips 26 is generally sufficient to hold the register in place when the opening O is in a floor. The clips can be suitable when the opening is in a building wall or ceiling, but a more positive locking mechanism is preferable in these instances. Thus, in one embodiment, a pair of cam locks 30 are provided at the opposite ends of the register 10, as shown in FIGS. 3-4. Each cam lock 30 includes a head 31 that defines a screwdriver slot 32. The head is positioned within the recess 16 and accessible from the top of the register, as shown in FIG. 2. The cam locks include a post 33 that extends through the bottom wall 17 to the underside of the register. A locking wedge 34 is affixed to the post 33 so that the wedge can be rotated relative to the bottom wall. The cam locks 30, and particularly the locking wedges 34, are configured so that when the locking wedges extend outward, as shown in FIGS. 3-4, the wedges engage the underside of the structure F, as shown in FIG. 5. The wedges can be rotated and retracted clear of the underside of the structure to allow removal of the register from the opening O. The wedges 34 can incorporate a notch 35 that engages the center rib 21 when the wedges are in their locking position. The engagement between the notches and the center rib retains the wedge in the locking position until it is intentionally rotated out of engagement by a screwdriver in the slot 32.

In one feature of the register 10, all of the features of the register, except for the cam locks 30, can be integrally formed so that the register is a one-piece component. The register can be formed of any suitable material, but a plastic is preferable for cost and manufacturability. The one-piece register can be produced in a conventional molding process or in an additive manufacturing process. In the latter process, the cam locks 30 can be produced at the same time as the rest of the register 10, with a frangible connection between the rotating elements of the cam locks and the side walls 25 or bottom wall 17.

The upper surfaces of the register can be decorative, such as by selecting a color or colors for the face plate 15 and the top surfaces 20a of the plenums 20. The top surfaces 20a can also incorporate decorative patterns or images as desired, or can be provided with decorative decals.

The present disclosure should be considered as illustrative and not restrictive in character. It is understood that only certain embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the disclosure are desired to be protected. For instance, in the illustrated embodiment, the register is rectangular to conform to the common rectangular air duct opening O. The features of the register can be modified for non-rectangular duct openings, such as a circular opening. For a circular register, the plenums can retain the rectangular configuration and extend across a chord of the circular opening. Alternative, the plenums can be in the form of concentric rings. Regardless of the shape of the duct opening and register, the vent openings 11 will be formed in side walls of the modified plenums and the top surface of the plenums will substantially cover the area of the opening.

Claims

1. A register for mounting on an opening of an air duct in a structure, the register comprising:

an annular face plate sized to be seated on a surface of the structure surrounding the opening;

a perimeter side wall extending generally perpendicularly from said face plate, the perimeter side wall sized and configured for a close fit with said structure within said opening;

one or more plenums, each plenum defined by a planar top surface and a perimeter wall, said one or more plenums supported by said perimeter side wall with said planar top surface of each plenum adjacent said annular face plate and defining a recess between said perimeter wall of said one or more plenums and said perimeter side wall, each plenum including; a plurality of transverse panels extending between opposite portions of said perimeter wall to define a plurality of cavities beneath said top surface, said cavities opening into the air duct when the register is mounted on the opening; and a plurality of vent openings defined in said perimeter wall between said recess and each of said plurality of cavities, whereby air from the air duct enters said plurality of cavities and flows through said plurality of vent openings and through said recess.

2. The register of claim 1, wherein said register is a one-piece body.

3. The register of claim 1, in which the opening of the air duct is rectangular, wherein said annular face plate is rectangular and said top surface of each plenum is rectangular.

4. The register of claim 3, wherein:

said perimeter wall of each plenum includes opposite side walls, extending along the long dimension of the rectangular shape of the plenum, and opposite end walls, and

said plurality of transverse panels extend between said opposite side walls.

5. The register of claim 3, wherein plurality of panels includes five panels and said plurality of cavities includes six cavities.

6. The register of claim 1, further comprising a bottom wall extending between said perimeter side wall and said perimeter wall of each of said one or more plenums, said bottom wall offset from said annular face plate and closing said recess from the air duct.

7. The register of claim 6, further comprising a plurality of ribs connected between said perimeter side wall and said perimeter wall of each plenum.

7. The register of claim 1, wherein said register is a one-piece body.

8. The register of claim 1, further comprising two plenums, wherein said recess is further defined between said two plenums.

10. The register of claim 1, in which the opening of the air duct is rectangular, wherein:

said annular face plate is rectangular;

said top surface of each plenum is rectangular;

said perimeter wall of each plenum includes an outer side wall facing said perimeter side wall, an inner side wall facing an inner side wall of the other plenum, and opposite end walls, and

said plurality of transverse panels extend between said outer side wall and said inner side wall of each plenum.

11. The register of claim 10, wherein plurality of panels includes five panels and said plurality of cavities includes six cavities for each plenum.

12. The register of claim 1, further comprising a plurality of resilient clips attached to the perimeter side wall, said clips configured and arranged to engage the underside of the structure at the opening to hold the register in the opening.

13. The register of claim 1, further comprising a cam lock at opposite portions of said perimeter side wall, said cam lock including a locking wedge rotatably attached to said perimeter side wall to rotate to and from a locking position in which the locking wedge engages the underside of the structure at the opening to hold the register in the opening.

14. The register of claim 12, wherein said cam lock includes a head defining a screw driver slot, said head disposed in and accessible through said recess.

15. The register of claim 1, further comprising an annular shroud extending from said annular side wall, said annular shroud having a dimension from said annular side wall of 0.125-2.0 ins.