Flush-Mounted Register Frame Assembly for Smooth Wall Finishing
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Solution Overview
Problem
Existing technologies for HVAC register frames do not provide a simple, cost-effective method for assembly and flush mounting that ensures a smooth interface with surrounding surfaces, lacking a frame construction made of extruded linear sections joined by L-shaped tab elements.
Innovation Solution
A frame apparatus composed of extruded metal or plastic linear sections joined by L-shaped tab elements, allowing for easy assembly and flush mounting by capturing wall putty between planar elements to create a smooth interface with the surrounding surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional register frames are constructed using conventional methods, then structural strength is maintained, but assembly complexity and manufacturing cost increase
Solution Approach 1:
The frame is divided into multiple linear extrusion sections that can be manufactured separately and then joined together using L-shaped tab elements, simplifying assembly while maintaining structural integrity
Solution Approach 2:
The L-shaped tab elements combine multiple functions: structural connection between sections, mounting attachment points, and alignment features, reducing the need for separate components
2Manufacturing precision
If traditional mounting methods are used, then secure attachment is achieved, but flush mounting with smooth interface is difficult
Solution Approach 1:
Wall putty or mud is used as an intermediary material between the frame and the wall surface, filling gaps and creating a smooth flush interface while simplifying the mounting process
Solution Approach 2:
The frame includes specific planar elements and mounting surfaces designed with local geometric features that facilitate putty application and ensure proper alignment for flush mounting
3Ease of manufacture
If extruded linear sections are used, then manufacturing cost is reduced, but connection strength between sections may be compromised
Solution Approach 1:
L-shaped tab elements are pre-formed as integral parts of the extruded sections, with built-in connection geometry that ensures proper alignment and strength when assembled
Solution Approach 2:
The connection system combines extruded metal or plastic sections with reinforced tab elements, creating a composite structure that maintains strength while enabling cost-effective manufacturing
Data Source
AI summary
A frame apparatus capable of being flush mounted relative to a wall, ceiling or floor surface, is made up 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 and with rib elements protruding from the third planar element, the mud is captured in place forming a smooth interface between the frame assembly and the surrounding wall surfaces.