Fixed plug for use in a process of forming an insulated register box
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming insulated register boxes often result in air leaks due to gaps between edges at corners and seams where multiple pieces are joined, and the process of insulating these boxes is labor-intensive, time-consuming, and costly.
Innovation Solution
A plug apparatus with a frame, a shaft, and multiple layers of flexible material is used to seal the interior of a duct during the process of forming an insulated register box, preventing expandable polymeric material from entering the duct and reducing the need for cleaning and scraping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sheet metal forming methods are used to create register boxes, then the structural strength is maintained, but air leaks occur through gaps at corners and seams
Solution Approach 1:
The patent combines multiple sheet metal pieces into a single formed structure with interlocking flanges and tabs. The register box is created from one or more sheets that are bent, folded, and formed into a unified structure where edges overlap and secure to one another, eliminating gaps and seams that would allow air leakage while maintaining structural integrity.
2Reliability
If manual insulation processes are used for register boxes, then insulation can be applied, but the process is labor-intensive and time-consuming
Solution Approach 1:
The patent incorporates insulation material directly into the register box formation process. Insulation is placed within the box structure before the final sealing steps are completed, allowing the insulation to be positioned and secured as part of the overall forming operation rather than requiring separate manual installation afterward.
3Manufacturing precision
If expandable polymeric material is used for insulation, then uniform insulation is achieved, but the material may enter and contaminate the duct interior
Solution Approach 1:
The patent removes the duct from the register box interior before applying expandable polymeric insulation material. By extracting or separating the duct component prior to the insulation expansion process, the expanding material is contained within the register box space and cannot enter or contaminate the duct interior, while still achieving uniform insulation coverage.
Solution Approach 2:
The patent takes preliminary action by positioning a barrier or shield between the expandable insulation material and the duct interior before the expansion occurs. This preventive measure blocks the harmful effect of material contamination while allowing the insulation to expand uniformly against the register box interior surfaces.
Data Source
AI summary
A plug apparatus for sealing an interior of a duct for use in a process for forming an insulated register box has a frame, a shaft extending outwardly of the of the frame, and a plurality of layers of flexible material radiating outwardly of the shaft adjacent to an end of the shaft opposite the frame. The plurality of layers of flexible material are adapted to have an outer periphery bearing against an interior surface of the duct. Each layer of flexible material has an outer diameter greater than an inner diameter of the duct. The flexible material is formed of a neoprene material. The frame is affixed to a support surface having an opening therein. The opening is adapted to receive an outer diameter of the duct therein.