MUD-IN HVAC COOLING REGISTER AND INSTALLATION METHOD WITH UNIVERSAL SUPPLY BOOT COMPATIBILITY

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Application No. 63/660,315, filed Jun. 14, 2024, which application is incorporated herein by reference in its entirety.

FIELD OF INVENTION

The present disclosure relates to HVAC construction and cooling registers, more specifically to connectors securing cooling registers to ductwork for the stable dispersal of conditioned air into a space.

BACKGROUND

Cooling registers, also known as air vents or grilles, are important components of HVAC systems that serve several crucial functions. Cooling registers direct and control the flow of conditioned air from the ductwork into the living spaces of a building. Many cooling registers feature adjustable louvers or dampers that allow users to control the volume and direction of airflow into a room. Filtration is key to many cooling register designs; the incorporation of filters helps remove dust, allergens, and other particles from the air as it enters the room. More generally, registers cover the openings of ductwork, preventing debris from entering the HVAC systems and sequestering the sharp edges of ductwork openings to both reduce maintenance costs and improve safety. Advanced cooling register designs can furthermore contribute to direct control of multiple degrees of air conditioning. Some modern cooling registers can be electronically controlled, allowing for integration with smart home systems for automated temperature and airflow management. In some instances, these registers may be part of a zoned setup, allowing for different temperature control in various areas of a building.

Some functions of cooling registers specifically necessitate a tight, stable joining and seal between said register and the register boot that supplies conditioned air from the central air handler. The tight, stable joining and seal between cooling registers and register boots is crucial for several reasons. Firstly, it ensures that conditioned air is efficiently directed into the intended space without leakage, which could lead to energy waste and reduced system performance. A secure connection also helps maintain proper air pressure within the ductwork, allowing for optimal airflow distribution throughout the building. Similarly, by minimizing gaps and vibrations at the connection point, securely joined registers can significantly dampen the sound of air rushing through the ducts, creating a quieter and more comfortable living environment. This is particularly important in residential settings, which often include noise-sensitive areas such as bedrooms or offices.

Properly sized, positioned, and sealed cooling registers furthermore contribute to energy efficiency and reduced environmental impact. When registers are correctly matched to the room size and layout, they ensure even air distribution, preventing hot or cold spots and reducing the workload on the HVAC system. This balanced airflow allows the system to operate more efficiently, potentially leading to lower energy consumption and reduced utility costs. In humid climates, the design of cooling registers plays a critical role in moisture management. Registers that are engineered to prevent or minimize condensation help protect surrounding surfaces from water damage, mold growth, and other moisture-related issues. This can be achieved through various means, such as incorporating thermal breaks, using materials with low thermal conductivity, or implementing designs that promote air circulation around the register to prevent the formation of cold spots where condensation is likely to occur.

The ability of cooling registers to address these various functions while maintaining aesthetic appeal is particularly relevant in the context of mud-in air registers. A mud-in cooling register is a type of HVAC vent with a low-profile frame that sits recessed within a floor, wall, or ceiling structure. Flanged edges allow for seamless integration with the surrounding drywall or plaster. The design enables the register to be plastered or “mudded” over, leaving only the central opening visible. This mud and occasionally an extruding visible portion of the register after installation is then sanded smooth and usually painted to match the surrounding surface. While cooling registers come in a variety of designs, materials, and finishes, mud-in cooling registers are specifically designed to provide a more streamlined and aesthetically pleasing appearance in finished spaces, minimizing the visual impact of the HVAC system. However, their integration with the surrounding wall makes maintenance a unique challenge. Close-fitting joiners between ductwork and cooling registers can prevent the misdirection of conditioned air, thereby ameliorating some of the needs for maintenance. However, current mud-in cooling registers are hampered by their inability to fit onto universal supply boot flanges, thereby complicating the installation process. The invention described in this disclosure teaches a cooling register that includes rear ridges compatible with supply boot flanges, the supply, as well as the simplified method necessary to install said register.

SUMMARY

An apparatus comprising a mud-in HVAC cooling register with accompanying rear ridges to facilitate installation upon a universal supply boot flange and said supply boot with protruding flange is provided, as is the method for installing said register. In one aspect, the present invention is a cooling register that securely attaches to a supply boot via a flange to permit the effective dispersal of conditioned air into a space. In another aspect, the present invention is a mud-in air register and supply boot with a simplified installation process to permit more effective workflow. In yet another aspect, the present invention is a method for the installation of a mud-in air register compatible with universal supply boots that permits register boot and mud-in air register installation prior to drywall installation. Generally, this disclosure describes a mud-in HVAC cooling register compatible with a universal supply boot and the accompanying method of installation.

The disclosed mud-in air register (interchangeably referred to herein as the “cooling register”) is an apparatus comprising a plane that, upon installation, faces the space receiving conditioned air (the “front;”) said front contains one or more openings permitting the flow of air through the register from the supply boot to the conditioned space. The opposite side of the apparatus facing the supply boot (the “rear”) further comprises a thin ridge of dimensions that permit it to snugly fit about the protruding flange of a supply boot. The exemplary register is rectangular, as is its corresponding ridge and the flange of the supply boot to which it fits; however, rectangularity is not a defining feature of this invention, and square, circular, ellipsoid, and other cooling register shapes and ridges for their accompanying boot are within the inventive disclosure. The front of the apparatus optionally includes peripheral holes or other sites for screws, bolts, and related means for affixing the cooling register to the supply boot. The rear ridges of the apparatus optionally include magnets for the purposes of securely affixing said ridges to the supply boot flange.

The disclosed register boot included in the invention comprises a tubular apparatus perpendicular to and terminating in the lateral face (the “first face”) of a hollow trapezoidal prism, wherein the trapezoidal prism has bases containing two adjacent vertices with angles measuring 90°, such that the superior lateral face of the prism is parallel to the anterior lateral face. The boot further comprises an opening of variable size and shape on the lateral face of the prism distal to the first face (the “second face.”) Said opening must have dimensions appropriate for the installation of a cooling register, and further comprise a protruding flange to facilitate attachment of a cooling register. The interior of the register boot lacks planes that would impede the flow of air from the tubular apparatus through the prism and out the distal opening. The tubular apparatus must be of dimensions appropriate to fit within or without of common HVAC ductwork openings. It may optionally contain elements intended to form a tight linkage with the ductwork to prevent loss of conditioned air supply, such as gaskets, flanges, or adjustable collars for fine-tuning the fit with the ductwork opening. Additionally, the tubular apparatus may incorporate features such as crimped edges or snap-lock mechanisms to facilitate easy installation and removal while maintaining a tight seal. These and similar design elements enhance the efficiency of air delivery and contribute to the overall energy efficiency of the HVAC system by minimizing air loss at connection points.

The method of installation for this device comprises the following steps: firstly, the register boot is affixed to the ductwork opening such that the conditioned air from the air handler can flow freely through the apparatus. Secondly, the cooling register is securely affixed to the second face of the register boot such that its rear ridges fit snugly about the protruding flange. Thirdly, drywall is installed about the system such that the cooling register, register boot, and ductwork are covered or otherwise integrated with the decor. Finally, the register is mudded-in, sanded, and painted to match the surrounding surface. This method differs from the prior art in that drywall can be installed about both the register and cooling register, allowing mudding in by the same installation team instead being required to wait for an HVAC technician to cut open the drywall and install the register.

The foregoing summary has outlined some features of the system and method of the present disclosure so that those skilled in the pertinent art may better understand the detailed description that follows. Additional features that form the subject of the claims will be described hereinafter. Those skilled in the pertinent art should appreciate that they can readily utilize these features for designing or modifying other systems for carrying out the same purpose of the system and method disclosed herein. Those skilled in the pertinent art should also realize that such equivalent designs or modifications do not depart from the scope of the system and method of the present disclosure. Further, it should be understood that the summary above is provided to introduce in simplified form a selection of concepts that are further described in the detailed description. It is not meant to identify key or essential features of the claimed subject matter, the scope of which is defined uniquely by the claims that follow the detailed description. Moreover, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure.

BRIEF DESCRIPTION OF FIGURES

These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:

FIG. 1 illustrates a front angled view of the cooling register, showing the front face, plurality of louvers, and peripheral sites for affixing means consistent with the principles of the present disclosure.

FIG. 2 illustrates a rear view of the cooling register, showing the rear face, rear ridges for accepting a supply boot flange, and an optional air damper installed within consistent with the principles of the present disclosure.

FIG. 3 illustrates a side view of the cooling register, including a breakdown of the components of the optional air damper consistent with the principles of the present disclosure.

FIG. 4 illustrates a side view of the supply boot, showing one trapezoidal base, the flange for attaching the invention, and the protruding tubular apparatus from the first face consistent with the principles of the present disclosure.

FIG. 5 illustrates the front view of the supply boot, including the cooling register installation consistent with the principles of the present disclosure.

FIG. 6 illustrates the bottom angled view of the invention with both the connector tube and cooling register site consistent with the principles of the present disclosure.

FIG. 7 illustrates a side, cross-sectional view of the supply boot and attached invention, showcasing one potential airflow pattern consistent with the principles of the present disclosure.

FIG. 8 illustrates a cross-sectional view of the invention as part of a mud-in air register installation behind a wall or ceiling and connected to the accompanying ductwork consistent with the principles of the present disclosure.

FIG. 9 illustrates a view of the invention connected to the accompanying ductwork with focus on the intersection of the tubular apparatus and ductwork openings consistent with the principles of the present disclosure.

FIG. 10 illustrates a flowchart in which the preferred method of installing the apparatus is detailed consistent with the principles of the present disclosure.

DETAILED DESCRIPTION

In the Summary above and in this Detailed Description, and the claims below, and in the accompanying drawings, reference is made to particular features, including method steps, of the invention. It is to be understood that the disclosure of the invention in this specification includes all possible combinations of such particular features. For example, where a particular feature is disclosed in the context of a particular aspect or embodiment of the invention, or a particular claim, that feature can also be used, to the extent possible, in combination with/or in the context of other particular aspects of the embodiments of the invention, and in the invention generally. The term “comprises” and grammatical equivalents thereof are used herein to mean that other components, ingredients, steps, etc. are optionally present. For example, an article “comprising” components A, B, and C can contain only components A, B, and C, or can contain not only components A, B, and C, but also one or more other components. As defined herein, the word substantial means more than half of the length.

FIGS. 1-10 illustrate multiple exemplary features of the system, designed for a mud-in installation, comprising a cooling register 100 and supply boot 200. FIG. 1 illustrates a top angled view of the front face 101 of the cooling register 100. FIG. 2 illustrates a rear view of the cooling register, including rear face 105 and site for screws 103. FIG. 3, illustrates an exploded view of the cooling register 100 and the air dampener 115, wherein the air dampener 115 is slidably attachable to the cooling register 100 and is magnetically controllable. FIG. 4 illustrates a detailed side view of the supply boot, highlighting its main components. FIG. 5 illustrates a front view of the supply boot, showcasing how the invention is installed onto the front face 203. FIG. 6 provides a back view of the supply boot, emphasizing the connection between the tubular apparatus 201 and the rear face 202. FIG. 7. illustrates the complete apparatus comprising both cooling register 100 and supply boot 200. Arrows within the figure illustrate the suggested pattern of airflow. FIG. 8 illustrates an embodiment of the invention wherein the supply boot 200 is affixed between two studs 301 in the wall of a structure. FIG. 9 illustrates a zoomed-in view of the apparatus accompanying ductwork in a junction. FIG. 10 illustrates a method for installing the cooling register 100 and supply boot 200. It is understood that the various method steps associated with the methods of the present disclosure may be carried out by one skilled in the art.

In a preferred embodiment, the cooling register 100 is an air vent comprising a front face, rear face, and a plurality of louvers that allow air to flow therebetween from said rear face to said front face. The front face of the cooling register 100 is preferably designed to have an aesthetically pleasing form while ensuring efficient airflow into the conditioned space. The rear face of the cooling register 100 is preferably configured to securely interface with a ventilation boot, ensuring a stable and airtight connection. A flow of air preferably moves through cooling register 100 via a plurality of openings situated between the plurality of louvers, wherein the plurality of louvers may be configured in a way such that they direct the flow of air into a conditioned space.

In one preferred embodiment, the angle in which the air directed by the plurality of louvers is a specific angle that is not changeable. Alternatively, the plurality of louvers may be configured in away such that the angel in which they direct a flow of air is adjustable, allowing for said plurality of louvers to direct a flow of air into a conditioned space at a custom angle. In some preferred embodiments, a dampener may be secured to the back face of the air dampener, allowing for a user to control a flow rate of a flow of air. In a preferred embodiment, the cooling register 100 is specifically designed for mud-in installation, which allows for seamless integration with the wall surface. This design approach is crucial for achieving a clean, unobtrusive appearance in the finished space.

The cooling register 100 may be planar and non-planar in design. However, the edges of the cooling register 100 are preferably designed in a way such that may be flush with a wall, ceiling, or floor surface when installed, allowing the cooling register 100 to be seamlessly integrated into said wall, ceiling, or floor surface, and ensuring that the cooling register 100 does not protrude or create any visual discontinuities. This seamless integration about the edges is particularly advantageous in high-end architectural applications where maintaining the visual integrity of the interior design is paramount. In a preferred embodiment, the cooling register 100 is planar, allowing for the cooling register 100 to blend into the surrounding surface, and providing a clean and unobtrusive appearance.

In another preferred embodiment, the cooling register 100 may be shaped in a way such that the outer edge area of the front face and/or back face of the cooling register 100 is not in plane with a central area of the front face and/or back face of the cooling register 100. This non-planar design allows for a cooling register 100 that is flush with a wall around its edges to allow for seamless integration into said wall while simultaneously allowing for said cooling register 100 to provide depth to an otherwise featureless surface. Accordingly, the central area of the cooling register 100 may be recessed or elevated relative to the outer edge area, creating a visually interesting and dynamic element within the wall surface. This non-planar design can be achieved through various means, such as a molding process, machining the cooling register 100 from a single piece of material, or assembling the cooling register 100 from multiple components. The choice of materials and manufacturing techniques will depend on the specific requirements of the installation, including factors such as durability, weight, and cost. For example, a register made from aluminum or stainless steel may be machined to create the desired shape, while a register made from a polymer such as ABS or PVC may be injection molded to achieve the same effect.

In another preferred embodiment, the cooling register 100 may further comprise aesthetic shape. The aesthetic shape of the cooling register 100 is preferably rectangular, as illustrated in FIG. 1, due to its simplicity and ease of integration into standard wall, ceiling, or floor openings. The rectangular design allows for straightforward alignment with the front face 203 of the register boot 200 and provides a clean, unobtrusive appearance when installed, as illustrated in FIG. 5. The rectangular shape also facilitates the creation of a uniform airflow pattern, which can be beneficial in maintaining consistent temperature and air distribution within the conditioned space. However, one with skill in the art will understand that a cooling register 100 may comprise other shapes without departing from the inventive subject matter described herein. The choice of shape can be influenced by various factors, including the specific requirements of the HVAC system, the architectural design of the space, and aesthetic preferences.

For instance, the cooling register 100 may comprise a square shape. The square shape offers similar benefits to the rectangular design, including ease of installation and a clean appearance. Additionally, the square shape can provide a more balanced airflow distribution, which may be advantageous in certain applications. The square design can also be more aesthetically pleasing in spaces where symmetry is a key design element. For instance, the cooling register 100 may comprise a circular shape. The circular shape can offer unique advantages in terms of airflow dynamics, as it can help to reduce turbulence and create a more even distribution of air. The circular design can also be more visually appealing in certain architectural styles, particularly those that emphasize curves and organic shapes. The circular register may be particularly well-suited for use in ceilings, where it can create a more diffuse and gentle airflow pattern. For instance, the cooling register 100 may comprise an ellipsoid shape. The ellipsoid shape combines elements of both circular and rectangular designs, offering a unique balance of aesthetics and functionality. The elongated shape of the ellipsoid register can help to direct airflow more precisely, which can be beneficial in spaces where targeted air distribution is required. The ellipsoid design can also add a distinctive visual element to the space, making it an attractive choice for high-end architectural applications.

For instance, triangular, hexagonal, or custom-shaped registers may be used in specialized applications where unique airflow patterns or design considerations are required. The choice of shape can also be influenced by the specific dimensions and layout of the ductwork and ventilation boot, as well as the desired aesthetic effect. The accompanying boot for each of these shapes is designed to match the corresponding register, ensuring a secure and airtight connection. The boot may include features such as flanges, gaskets, or other sealing mechanisms to enhance the stability and performance of the system. The design of the boot and register combination is intended to provide optimal airflow while maintaining a seamless and integrated appearance within the space. The chosen aesthetic shape may be combined with a non-planar design to create a particularly unique and seamless design with a wall, ceiling, or floor.

In a preferred embodiment, as illustrated in FIG. 1, the front face 101 of the cooling register serves as the visible part of the unit once installed. The front contains an aperture crossed by a plurality of louvers 102 for the purpose of directing conditioned air outwards. The aperture with louvers 102 is a critical functional element, allowing for the controlled release of conditioned air into the room. These louvers can be designed to direct airflow in specific patterns or angles, optimizing air distribution and enhancing overall comfort in the space. The plurality of louvers is designed to allow for efficient airflow while minimizing noise and turbulence. The plurality of openings created by the plurality of louvers may take various forms, such as slots or perforations, depending on the specific airflow requirements and aesthetic preferences. The size, shape, and arrangement of the openings can be optimized to ensure that the register provides the desired level of air distribution while maintaining a low profile and unobtrusive appearance. In some embodiments, the plurality of louvers may be adjustable, allowing the user to control the direction and volume of airflow through the plurality of openings. In one preferred embodiment, this may be achieved through the use of adjustable louvers or dampers that can be manually or electronically controlled. Adjustable openings provide greater flexibility in managing the indoor climate and can contribute to improved energy efficiency by allowing for more precise control of air distribution.

In a preferred embodiment, the periphery of the register is scored to facilitate adherence of the mud to its surface, permitting a more secure join with the surrounding wall. This scoring process involves creating small grooves or indentations along the edges 104 of the register, which serve as mechanical keying features that enhance the bond between the register and the plaster or mud used in the installation process. The scored surface increases the surface area available for the mud to adhere to, thereby improving the mechanical interlock between the register and the wall material. This method is particularly effective in ensuring that the register remains securely in place even under conditions of thermal expansion and contraction, as well as mechanical stresses such as those caused by building settling or vibrations. This feature is crucial for maintaining the integrity and appearance of wall surfaces in which cooling registers 100 are installed, particularly in high-end architectural applications where the visual continuity of wall surfaces is paramount.

In a preferred embodiment, as illustrated in FIG. 2, the rear face 105 serves as the interface between the register and the supply boot, while the sites for screws 103 provide additional securing points for installation. However, the most crucial element of this figure is the set of ridges 106. These ridges are a defining feature that sets this cooling register 100 apart from conventional mud-in air register designs. Their primary function is to allow the register to fit directly and securely around the protruding flange of a supply boot opening. This direct fitting mechanism ensures a tight, stable connection between the register and the boot, which is critical for maintaining the efficiency of the HVAC system by preventing air leakage and ensuring proper airflow. In a preferred embodiment, an air damper 115 adds an extra layer of functionality to the register, wherein the air dampener is preferably configured for magnetic operation that allows for easy adjustment of airflow without the need for manual manipulation of physical levers or sliders that would otherwise protrude from the wall and disrupt the seamless appearance of a mud-in cooling register. Furthermore, the air damper 115 enables fine-tuning of the airflow into the conditioned space, potentially improving energy efficiency and occupant comfort by allowing for more precise control over air distribution.

The rear face of the cooling register 100 preferably comprises a ridge or set of ridges configured to accept a protruding flange of a register boot. These ridges are designed to create a tight and secure fit with the protruding flange, ensuring that the cooling register 100 remains firmly in place during operation. In a preferred embodiment, the rear ridges are configured to snugly fit about the protruding flange, creating a tight, frictional fit. This frictional fit is facilitated by the precise dimensions of the rear ridges, which are engineered to have dimensions that are slightly larger than the dimensions of the protruding flange (i.e. approximately 1 mm or less). In some preferred embodiments, the rear ridges may include an inner lip or groove that engages with the edge of the protruding flange, providing additional mechanical stability. This lip or groove acts as a catch, preventing the flange from slipping out of the ridges once it is inserted. In other preferred embodiments, the inner lip may be textured in a way that further increase the friction force generated between the protruding flange and the rear ridges.

In another preferred embodiment, the rear ridges may be designed with a slight inward taper. This taper allows the ridges to compress slightly as they are pushed onto the protruding flange, thereby creating a tight seal. The inward taper ensures that the flange is gripped firmly by the ridges, reducing the likelihood of air leakage and maintaining optimal airflow through the HVAC system. In yet another preferred embodiment, the ridges may include flexible tabs or fingers that snap into place over the protruding flange, allowing for the cooling register 100 to be removably secured to the boot prior to mudding in. The flexible nature of the tabs or fingers ensures that they can accommodate slight variations in the size and shape of the protruding flange, providing a secure fit even in cases where the flange dimensions are not perfectly uniform. This may be a particularly useful feature in instances where the cooling register 100 is prone to dimensional inconsistencies resulting from material and/or process inconsistencies, such as those experienced when using an injection molding process with certain types of thermoplastics.

In some preferred embodiments, the front face of the cooling register 100 includes peripheral holes or other sites for screws, bolts, and related means for affixing the cooling register to the supply boot. The peripheral holes or sites for screws and bolts provide a secure mechanical connection between the cooling register and the supply boot, ensuring long-term stability and preventing unwanted movement that could lead to air leaks or misalignment. This is particularly important in systems subject to vibration or in buildings that may experience settling over time. It is recommended in the majority of embodiments that such sites be utilized to ensure the register does not shift or leak during installation. In a preferred embodiment, the ridge on the cooling register contains magnets capable of attaching to the protruding flange on the supply boot, provided the flange is made of magnetizable metal. Similarly, in another preferred embodiment the cooling register ridge features fine-threaded adjustment mechanisms or ratcheting systems that allow for precise, incremental adjustments to achieve the perfect fit.

In some preferred embodiments, the attachment mechanism may incorporate a combination of these methods. For example, a design might use magnets for initial positioning and easy alignment, followed by the use of screws or bolts for final secure attachment. This hybrid approach could offer the benefits of both quick installation and long-term stability. Furthermore, in systems where frequent access for cleaning or maintenance is required, designers might opt for quick-release mechanisms that still maintain a secure seal when engaged. These could include quarter-turn fasteners or spring-loaded clips that provide a tight connection but can be easily disengaged when necessary.

In another preferred embodiment, the join between the register and the supply boot is sealed with a gasket to prevent the leakage of either air or condensation. The gasket seal between the register and supply boot is a critical component in maintaining system efficiency and preventing potential damage to surrounding structures. By creating an airtight seal, the gasket prevents conditioned air from escaping into wall cavities or other unintended spaces, which could lead to energy waste and reduced system performance. Additionally, the gasket serves as a barrier against condensation, which is particularly important in humid environments or in cooling applications where the temperature differential between the conditioned air and the surrounding environment can lead to moisture accumulation. The choice of materials for these attachment components and sealing components is also crucial. In embodiments incorporating gaskets, it is recommended that the gaskets may be made from materials with specific durometer ratings to provide an optimal balance between compressibility and resilience, ensuring a long-lasting seal under various environmental conditions. For instance, gaskets may be made from materials such as EPDM rubber or silicone, which offer excellent resistance to temperature extremes and maintain their sealing properties over extended periods. Magnetic components may use rare earth magnets like neodymium for their strong magnetic fields, while ensuring they are properly coated or encased to prevent corrosion from exposure to condensation. By carefully considering and implementing these various attachment methods and sealing methods, manufacturers can ensure that the cooling register remains securely in place, maintains an efficient seal, and contributes to the overall performance and longevity of the HVAC system.

In some preferred embodiments, the rear ridges of the cooling register may also include a locking mechanism that can be engaged once the flange is fully inserted. This locking mechanism ensures that the cooling register 100 remains securely attached prior to being mudded into place. For ease of installation, the ridges may include alignment marks or guides. These marks or guides help ensure proper positioning and orientation of the cooling register 100 during installation on the supply boot 200, reducing the risk of misalignment and ensuring a secure fit. The alignment marks or guides may be visual indicators or physical features such as notches or ridges that align with corresponding features on the protruding flange.

As illustrated in FIG. 3, the various components of the cooling register 100, including steel keys 107, magnets (slider catch magnet 108, 114), slider catch 110, slider catch 111, rollers 112, and retaining clips 113, work together to create a smooth, adjustable mechanism for controlling airflow. Furthermore, in the illustrated embodiment, side magnets 109 may be used to facilitate the adherence of the register to the protruding supply boot flange, which in many embodiments is constructed of magnetizable metal. The use of magnetic components in the damper system permits a design that prioritizes ease of operation and maintenance. Magnetic mechanisms can offer smooth, quiet operation and may be less prone to wear compared to purely mechanical systems. Additionally, the use of multiple magnets and configurations contributes to the stability and reliability of the damper's operation.

In a preferred embodiment, as illustrated in FIG. 4, a protruding flange 206 on the front of the apparatus is designed to interface with the cooling register 100, providing a secure attachment point and ensuring a proper seal between the supply boot and the register. The tubular apparatus 201 of the supply boot 200 serves as the primary connection point to the HVAC ductwork, allowing for the efficient transfer of conditioned air. The tubular apparatus preferably transitions into the rear face 202 of trapezoidal prism shape, as illustrated in FIG. 6. The bases 204 of this prism are specifically designed with two adjacent 90° angles, creating a stable and geometrically precise structure. This configuration is essential for ensuring proper airflow dynamics within the boot. The construction of the supply boot involves folded faces joined by a riveted seam 205. This method of assembly provides structural integrity while allowing for potential disassembly if maintenance is required. The riveted seam also contributes to the boot's ability to maintain an airtight seal, which is crucial for preventing air leakage and maintaining system efficiency.

In another preferred embodiment, the seam is not a riveted seam but is welded in place. Welding the seam provides a more permanent and potentially more airtight seal compared to riveting. Spot welding is suggested as a technique to temporarily hold the seam in place while the full weld is completed. This approach allows for precise alignment of the components before the final, continuous weld is applied. The resulting seam is likely to be more resistant to air leakage, which is crucial for maintaining the efficiency of the HVAC system. In another preferred embodiment, the seam is soldered into place. Soldering offers a middle ground between riveting and welding in terms of permanence and ease of disassembly. This method can provide a good seal while potentially allowing for easier disassembly compared to welding, should maintenance or replacement be necessary. In another preferred embodiment, the soldered seal is supplemented with bolts, rivets, or screws, which improve the strength of the seam and hold it in place during the soldering process.

The trade-off in welded or soldered embodiments is significant: while these methods may improve the air seal, they also complicate the manufacturing process and make future disassembly more challenging. This consideration is important for several reasons. Welding or soldering processes may require more specialized equipment and skilled labor compared to riveting, potentially increasing production costs. Similarly, ensuring consistent weld or solder quality across all units may be more challenging than inspecting riveted joints. From a maintenance and repair perspective, welded or soldered seams may be more difficult to disassemble for cleaning, repair, or replacement of internal components. This could impact the long-term serviceability of the supply boot. Finally, the choice between welding and soldering may be influenced by the material of the supply boot, as not all materials are equally suitable for both processes.

Even with theoretically compatible materials, the heat involved in welding or soldering processes could potentially affect the material properties or dimensions of the supply boot, requiring careful control of the manufacturing process. These alternative construction methods reflect a balance between achieving optimal air seal performance and maintaining practical considerations for manufacturing and maintenance. The choice of method would likely depend on factors such as the specific application requirements, production volume, expected service life, and anticipated maintenance needs of the HVAC system in which the supply boot is installed. One skilled in the art of HVAC installation and repair is recommended to consider their particular system with care.

In a preferred embodiment, as illustrated in FIG. 7, the conditioned air directed by the central air handler enters the supply boot 200 through the tubular apparatus 201. This tubular apparatus serves as the primary connection point between the HVAC ductwork and the supply boot, ensuring a smooth transition of airflow from the main system into the register assembly. Within said boot, it circulates under compression before being forced out through the apertures in the cooling register 100. This compression is intended to increase the air's velocity, which can help in projecting the air further into the room. It furthermore creates a more uniform distribution of air pressure within the boot, which contributes to even airflow through the register. The louvers 102 within the cooling register are preferably angled so as to direct the flow of air at a descending angle relative to the installation surface and front face 101. This descending angle serves several functions; in high-mounted cooling registers, it creates a more comfortable environment by directing cool air downward, where occupants are more likely to feel its effects. Additionally, the descending angle can promote better air mixing within the room, potentially improving overall temperature distribution and reducing stratification. By directing air downward, it may help to prevent the Coanda effect, where air tends to cling to surfaces, which can lead to uneven cooling and potential condensation issues on walls or ceilings.

As illustrated in FIG. 8, wall studs provide a stable and secure mounting point within the wall cavity. The protruding flange 206 faces into the space meant to receive conditioned air, upon which the cooling register shall be affixed prior to the installation of drywall material. The ability to affix the cooling register prior to drywall installation is a key feature of this invention, as it streamlines the construction process and ensures a more integrated final appearance. Furthermore, the placement of the supply boot between wall studs and its connection to the ductwork before drywall installation allows for easier access during the construction phase. This can facilitate any necessary adjustments or inspections before the wall is closed up, potentially reducing the need for future repairs or modifications that might damage finished surfaces. This method contrasts with traditional approaches where the mud-in air register might be installed after the drywall, potentially leading to less seamless integration and requiring additional finishing work.

In a preferred embodiment, as illustrated in FIG. 9, the tubular apparatus 201 of the supply boot serves as the connection point to the HVAC ductwork, which allows for efficient air transfer from the main HVAC system to the individual room or space. The ductwork opening 302 is not an isolated component but is integrated into the broader HVAC infrastructure of the building, as indicated by its link to the remainder of the structure's HVAC ductwork 303. This interconnection emphasizes the systemic nature of HVAC design, where each component must work in harmony with the others to ensure optimal performance. As previously mentioned, the tubular apparatus 201 is preferably designed to integrate seamlessly with existing ductwork, ensuring effective delivery of conditioned air without obstruction and is crucial for maintaining airflow integrity, minimizing resistance, and preventing leaks that could compromise efficiency. The ductwork opening 302 allows for a flow of air to move from the ductwork to the supply boot and into a building expanse via the cooling register. The connection between the tubular apparatus 201 and the ductwork opening 302 is preferably engineered for a secure, airtight seal, vital for maintaining air pressure and flow rate.

FIG. 10 depicts a flow chart 1000 illustrating certain, preferred, method steps that may be used to carry out the method of installing a mud-in air register having rear ridges capable of accepting a flange and integrating said mud-in air register into a wall, ceiling, or floor. Step 1005 indicates the beginning of the method. During step 1010, a user may obtain a register boot having a protruding flange and a mud-in air-register configured to secure to said protruding flange. Once obtained, a user may secure the register boot to wall during step 1015. In one preferred embodiment, the register boot is affixed to the frame of the wall. The user may then secure ductwork about a first opening of the register boot during step 1020. In a preferred embodiment, the ductwork is secured about the first opening of the register boot in a way such that the flow of air supplied by the air supply can move freely from the ductwork to the register boot.

Once the ductwork is secured about the first opening of the register boot, the user may secure the mud-in air register about a second opening of the register boot during step 1025. This connection is critical for maintaining the integrity of the system and preventing air leakage. The snug fit between the register's rear ridges and the boot's flange creates a seal that helps maintain proper air pressure and flow. As mentioned previously, depending on the specific design, this attachment may be further enhanced through various means such as screws, clips, or magnetic connections as described previously. After the mud-in air register is secured to the register boot, wall material may be installed onto the wall frame about the mud-in air register and register boot during step 1030, wherein the wall material is substantially even with the outer areas of the front face of the mud-in air register. In a preferred embodiment, the wall material is drywall. This step requires careful measurement and cutting to ensure that the wall material is substantially flush with the outer edge of the front face of the mud-in air register. The integration of the front face of the mud-in air register with the wall material is a key aspect of this invention, allowing for a more seamless and aesthetically pleasing installation. The user may then apply wall filler about the mud-in air register during step 1035 in order to seamlessly integrate the mud-in air register into the wall. Once the user has integrated the mud-in air register into the wall, the method may proceed to terminate method step 1040. In some preferred embodiments, the user may perform finishing steps, such as sanding and painting, before proceeding to the terminate method step.

This streamlined approach offers several advantages: the installation can be completed in fewer steps and with fewer personnel, potentially reducing labor costs and installation time. Similarly, by allowing the drywall and finishing team to complete the entire process, there is a higher likelihood of achieving a seamless, professional-looking result; eliminating the need for an HVAC technician to cut into finished drywall reduces the risk of accidental damage to the surrounding area. Additionally, this method simplifies project management by reducing the need to coordinate between different trades, potentially speeding up the overall construction or renovation process. The ability to install the register before or after drywall installation provides more options for construction sequencing, which can be particularly beneficial in complex renovation projects.

The materials used to construct the various components of the system preferably comprise materials common in HVAC systems, including but not limited to galvanized steel, aluminum, stainless steel, and various polymers such as ABS (Acrylonitrile Butadiene Styrene) or PVC (Polyvinyl Chloride). Galvanized steel is often chosen for its durability, corrosion resistance, and cost-effectiveness, making it suitable for both residential and commercial HVAC applications. Aluminum is valued for its lightweight properties and excellent heat conductivity, which can be beneficial in certain cooling register designs. Stainless steel, while more expensive, offers superior corrosion resistance and is often used in high-end or specialized HVAC installations where longevity and aesthetics are paramount. Polymers like ABS and PVC are increasingly popular in HVAC component manufacturing due to their versatility, ease of molding into complex shapes, and resistance to moisture and chemicals.

Additionally, some embodiments may incorporate composite materials or alloys that combine the beneficial properties of multiple materials to achieve optimal performance characteristics such as strength, thermal insulation, and vibration dampening. Furthermore, surface treatments such as anodizing, nitriding, or application of a lubricious coating to one or more parts of the register boot can improve functionality. For instance, anodizing metals can reduce susceptibility to corrosion and improve insulation, thereby mitigating the impact of condensation and improving energy efficiency. Nitriding can enhance wear resistance, thereby extending the lifespan of the boot. The application of a lubricious coating to register components which connect to the register boot can facilitate the replacement of parts during necessary maintenance and repairs.

In most preferred embodiments, the selection of materials for the cooling register takes into account factors such as thermal expansion, acoustic properties, and compatibility with existing HVAC components. This careful consideration ensures that the register can maintain a secure and stable connection with the register boot across a wide range of operating conditions, including temperature fluctuations and air pressure variations typical in HVAC systems. The surface finish of internal features may also be considered in the design. A smooth, polished surface can minimize friction and turbulence, while a slightly textured surface might be beneficial in certain scenarios to promote a thin boundary layer and reduce flow separation. The above list of materials, though selected for useful properties common in HVAC system construction and design, should not be construed as exhaustive. One of ordinary skill in the art is capable of selecting another material to construct the invention, based on their best judgment and the system in question.

In a preferred embodiment, the interior of the register is designed with smooth, unobstructed surfaces, lacking planes that would impede the flow of air from the register boot through the register and out the front. In a different preferred embodiment, however, the addition of internal planes to direct air current in register boots with shallow angles may maximize airflow direction at the cost of efficiency. The interior surfaces of the register may be designed with additional features to further enhance airflow efficiency and reduce turbulence. These features may include rounded corners or fillets at junctions between surfaces, which can help to smooth air transitions and minimize areas of potential flow separation. In some cases, the interior surfaces may be treated with specialized coatings or finishes that reduce friction and resist the buildup of dust and debris, maintaining optimal airflow characteristics over time. Those skilled in the art may thereby exercise their best judgment about the optimal internal arrangement for their system for their airflow requirements.

In preferred embodiments with a system subject to heavy usage, the register may also incorporate features to enhance its thermal performance. This may include the integration of insulation materials within the boot's structure or the use of double-walled construction to create an air gap that reduces heat transfer between the conditioned air and the surrounding wall. In addition to insulation materials and double-walled construction, advanced thermal management techniques may be employed. For instance, the use of reflective coatings on internal surfaces can help redirect radiant heat, further reducing unwanted heat transfer. Some embodiments may incorporate phase change materials (PCMs) within the boot's structure, which can absorb and release thermal energy as they change state, helping to stabilize temperatures and reduce peak loads on the HVAC system. For applications in extreme temperature environments, such as industrial settings or regions with severe weather conditions, the register boot may incorporate more robust insulation solutions. This could include vacuum-insulated panels or aerogel-based insulation, which offer superior thermal resistance in a compact form factor. Additionally, the use of composite materials with low thermal conductivity can provide structural strength while minimizing heat transfer.

In systems where condensation is a significant concern, such as in tropical or subtropical climates, the register may be designed with integrated drainage channels or moisture-wicking materials to manage any condensate that forms. This can prevent water accumulation and potential mold growth, which could otherwise compromise indoor air quality and the structural integrity of surrounding building materials. To further enhance energy efficiency, some embodiments may feature dynamic insulation systems that can adjust their thermal properties based on environmental conditions. This could involve the use of smart materials that change their insulative properties in response to temperature fluctuations, or mechanically adjustable air gaps that can be modified to optimize thermal performance based on seasonal needs or specific usage patterns. These advanced thermal management features not only contribute to the overall energy efficiency of the HVAC system but also help to extend the lifespan of the register and surrounding building components by mitigating the effects of thermal stress and moisture-related issues. By incorporating such features, the register becomes an active participant in the HVAC system's thermal management strategy, rather than a passive conduit for conditioned air.

The implementations set forth in the foregoing description do not represent all implementations consistent with the subject matter described herein but are examples consistent with the disclosed subject matter. Although variations have been described in detail above, other modifications or additions may be possible. In particular, further features and/or variations may be provided in addition to those set forth herein. For example, the implementations described above may be directed to various combinations and subcombinations of the disclosed features and/or combinations and subcombinations of several further features disclosed above. In addition, the logic flow depicted in the accompanying figures and/or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. It will be readily understood to those skilled in the art that various other changes in the details, materials, and arrangements of the parts and method stages which have been described and illustrated in order to explain the nature of this inventive subject matter may be made without departing from the principles and scope of the present disclosure.