Nested-Box Register Assembly for Flush-Mounted Aesthetic Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional air vent registers are aesthetically unpleasing and costly, requiring specialized tools and expertise for customization to match surrounding surfaces, and are often unpleasant to tread upon.
Innovation Solution
A modular register assembly comprising a register body and insert, with a customizable faceplate, where the insert is nested within the body and secured using a male-female locking mechanism, allowing for easy customization and integration with various surface materials, and optional features like dampers or humidifiers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional faceplates are manufactured to be slightly larger than the duct opening to overlap surrounding surfaces, then the faceplate can be securely installed, but the faceplate extends away from the surface creating an unsightly appearance and unpleasant tactile experience
Solution Approach 1:
The register assembly uses nested boxes where the first box is received within the second box, creating a compact structure that sits flush with the surface. The restraint mechanism further secures the nested configuration, achieving both flush mounting and secure installation.
Solution Approach 2:
The register is divided into multiple components (first box, second box, support, restraint) that can be assembled together. This segmentation allows the faceplate to be constructed in a way that achieves flush mounting while maintaining secure installation through the interlocking components.
2Shape
If custom-made registers are manufactured to blend in with surrounding walls, floors and ceilings, then the appearance is improved, but special tools and expertise are required and the cost increases
Solution Approach 1:
The register assembly uses standard box sections that can be universally applied to different locations and surfaces. The modular design allows the same basic components to be used for various customization needs without requiring special tools or expertise, reducing both complexity and cost.
Solution Approach 2:
The register assembly allows for dynamic customization through the selection and arrangement of different faceplate materials and designs while using the same standardized box structure. This enables aesthetic customization without increasing manufacturing complexity.
3Reliability
If the register components are securely restrained within each other, then the installation reliability is improved, but the device complexity increases
Solution Approach 1:
The restraint mechanism is merged with the box structures themselves, using integral features of the boxes (such as flanges or interlocking edges) to provide restraint. This integration reduces the need for separate, complex restraint components while maintaining secure installation.
Data Source
AI summary
In one embodiment, the invention is a register assembly for inserting into floors, ceilings and walls, comprising a first open top box having a bottom surface, which defines a centrally disposed opening through which air flows from a first environment to a second environment. A support is disposed within the first open top box. A second open top box nests within the first open top box, and is supported by the support. A restraint is associated with the first and second box to restrain the second box within the first box. The first and second open top boxes are sized and dimensioned to be coplanar with each other when nested. A conduit is also defined between the first open top box bottom surface opening and the second open top box to flow air from the first environment to the second environment.