Note: Descriptions are shown in the official language in which they were submitted.
TITLE OF THE INVENTION
[0001] REFLECTIVE LAMINATE INSULATING ASSEMBLY
CROSS-REFERENCE TO RELATED APPLICATIONS
[0002] None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR
DEVELOPMENT
[0003] None.
REFERENCE TO A "SEQUENCE LISTING"
[0004] None.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[0005] The present disclosure relates to insulated HVAC duct components
and more specifically to after market pre-formed insulating components and
insulated HVAC transition boxes having a first insulation layer and a second,
different insulation layer.
DESCRIPTION OF THE RELATED ART
[0006] The insulation of ducts, such as HVAC ducts, provides a number of
benefits including energy efficiency and noise reduction. Typically, mineral
wool insulation is placed inside or outside duct components to provide such
benefits. Recent changes in building codes and regulations, however, now
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require that transition boxes, including register boxes, have increased R
values. To increase the R value of and resist thermal transfer in HVAC
systems, an increased amount of mineral wool insulation can be used.
However, while the thickness of the insulation increases the R value, the
increased thickness does not fit within a standard size transition box. For
example, a register box typically includes a space of two inches or less
between a back wall and a collar and between the sidewalls and the lip of the
register box. Although the insulation material can be compressed to fit
inside the transition box, this reduces the R value and does not provide
sufficient insulation. While the size of the register box can be increased,
this
is costly, not aesthetically pleasing, and reduces available operable
locations
for the box.
[0007] What is needed then is a transition box which can be manufactured
with existing technology and allow installation in existing formats, wherein
the register box has increased resistance to thermal transfer. The need also
exists for a register box that can be constructed in a relatively reduced
size,
thereby allowing installation into previously unattainable spaces, while
meeting industry or municipal standards for resistance to thermal transfer. A
need also exists for an insulating component that can be transported
(shipped) in a first configuration and formed into a second operable
configuration without requiring any assembly by the installer.
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BRIEF SUMMARY OF THE INVENTION
[0008] The insulated HVAC duct component of the present system provides
for increased resistance to thermal flow and can be constructed with reduced
insulation thickness allowing insulation in smaller formats or installation of
higher R value transition boxes in previously unavailable locations while
meeting increasing municipal or industry standards for resistance to thermal
flow.
[0009] In one configuration, the insulated HVAC duct component comprises
a register box having two sets of opposing sidewalls, a bottom wall, and a
top wall having a rectangular outlet and a lip extending into the register
box.
A mineral wool layer having a first R value is adjacent the inside surface of
the box and a reflective laminate layer having a second R value overlies the
mineral wool layer.
[0010] The insulated HVAC duct component can include an adhesive
intermediate the mineral wool layer and the reflective laminate layer. In one
construction, the reflective laminate layer includes a base piece of
reflective
laminate material sized to overlap the bottom wall and two opposing
sidewalls of the register box, and side pieces of reflective laminate material
sized to overlap the other two opposing sidewalls to dispose the mineral wool
intermediate the respective wall and the reflective laminate layer. The back
wall of the register box can also include a circular inlet and a collar,
wherein
the base piece of reflective laminate material includes an aperture for
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receiving the collar. The mineral wool layer and the reflective laminate layer
can be removably secured or retained within the register box by the lip.
[0011] In another configuration, an insulated register box for a HVAC duct
system is provided, wherein the register box includes four sidewalls forming
four corners, an outer mounting flange, a bottom wall having a circular inlet
having a collar, and a top wall having a rectangular outlet and an inner rib,
the inner rib protruding from the top wall and extending into the rectangular
box. A first layer of insulation material having a first R value is adjacent
inside portions of the sidewalls, the back wall and front wall. The first
layer
can engage the lip of the front wall. A second layer of a different insulation
material having a second R value is adjacent outside surface of the sidewalls
and back wall. The second layer includes an aperture for receiving the collar
of the rectangular box.
[0012] In yet another configuration, the insulated HVAC duct component
includes a transition box at least four sidewalls and one of a top and a
bottom wall. The transition box includes a first access port and a second
access port, wherein the first access port has a different cross section than
the second access port. One of the access ports is spaced from a nearest
sidewall by less than 2 inches. A first insulation layer is located along an
inside surface of the box and a different second insulation layer overlies the
first insulation layer to form a composite. The second different insulation
layer has an air impervious surface. The combined thickness of the first
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insulation layer and the second different insulation layer is less than 2
inches.
In a further configuration, the composite has an R value of at least 8.
[0013] A method of insulating a transition box is provided including
locating a first insulation layer along an inside surface of a transition box
and
overlying a second air impervious insulation layer on the first insulation
layer,
wherein the second insulation layer is different from the first insulation
layer
and wherein a combined thickness of the first insulation layer and the second
different insulation layer is less than 2 inches. An adhesive layer may be
applied intermediate the first insulation layer and the second insulation
layer.
A die cut aperture can be formed in the first and second insulation layer
sized
to receive a collar of the transition box. The method can also include
locating
a perimeter edge of the first and second insulation layers behind a lip of the
transition box.
[0014] Another method of insulating a transition box includes locating a
first insulation layer having a first R value along an inside surface of a
transition box, engaging a perimeter edge of the first insulation layer with a
lip of the transition box, locating a second insulation layer having a second
R
value along an outside surface of a transition box, and folding triangular
corner tabs of the second insulation layer against an outer surface of the
second insulation layer. The triangular corner tabs can be secured to the
transition box and/or the outer surface of the second insulation layer.
Date Recue/Date Received 2022-09-02
[0015] In a further configuration, an insulating assembly for an HVAC duct
component is provided, wherein the insulating assembly includes a reflective
laminate body having a base, a first sidewall extending from the base and a
second sidewall extending from the base, at least one of the sidewalls
terminating at a free edge; the base and the sidewalls movable between a
first transport configuration wherein a majority of the base and a majority of
each of the sidewalls are parallel and an installation configuration wherein
the
sidewalls are inclined relative to the base; and the reflective laminate
including an upper reflective layer, a bottom reflective layer and a cellular
layer intermediate the upper reflective layer and the bottom reflective layer.
[0016] In one configuration, a portion of the first sidewall of the
insulating
assembly is affixed to a portion of the second sidewall, independent of the
base. The portion of the first sidewall can be affixed to the portion of the
second sidewall by a fastener. It is contemplated the base, the first sidewall
and the second sidewall can be integral.
[0017] In a further configuration, the least one of the base, the first
sidewall and the second sidewall includes a line of weakness for removing a
corresponding portion of the at least one of the base, the first sidewall and
the second sidewall. In an alternative construction, at least one of the base,
the first sidewall and the second sidewall includes a cutout removing a
corresponding portion of the at least one of the base, the first sidewall and
the second sidewall.
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[0018] A layer of mineral wool can be operably located adjacent to one of
the first sidewall and the second sidewall and the base. The layer of mineral
wool can be parallel to and spaced from one of the first sidewall and the
second sidewall and the base.
[0019] The insulating assembly can further include a first polymeric layer
bonded to the upper reflective layer, the cellular layer bonded to the first
polymeric layer, a second polymeric layer bonded to the cellular layer and the
bottom reflective layer bonded to the second polymeric layer.
[0020] The insulating assembly can include a fold line between each of the
sidewalls and the base and in select configurations, least one of the fold
lines
can include a score line.
[0021] The insulating assembly can further include a third sidewall and a
fourth sidewall, wherein each of the third and fourth sidewalls includes a
collapsing fold line.
[0022] The insulating assembly can further include an adhesive on an
exposed surface of one of the base and the sidewalls.
[0023] The insulating assembly can cooperatively engage an HVAC
component, such as a transition box, thermally coupled to the reflective
laminate body. The reflective laminate body can be located adjacent an
inside surface of the transition box. Alternatively, the reflective laminate
body can be adjacent an outside surface of the transition box.
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[0024] The insulating assembly can further include a second reflective
laminate body, wherein the reflective laminate body is adjacent an outside
surface of the transition box and the second reflective laminate body is
adjacent an inside surface of the transition box.
[0025] Another method is provided of moving a plurality of sidewalls of a
reflective laminate insulating assembly from a first transport configuration,
wherein a majority of a base and a majority of each of the plurality of
sidewalls are parallel to an installation configuration, wherein each of the
plurality of sidewalls is inclined relative to the base; and disposing the
reflective laminate insulating assembly in the installation configuration
about
a portion of an HVAC duct component to inhibit thermal transfer to or from
the HVAC duct component.
[0026] In one version, the HVAC duct component can be metallic, and
wherein the HVAC duct component can be an HVAC transition box.
[0027] The method can also include locating the reflective laminate
insulating assembly adjacent an inside surface of the HVAC duct component.
[0028] Similarly, the method can include locating the reflective laminate
insulating assembly adjacent an outside surface of the HVAC duct
component.
[0029] A method is provided including cutting a planar sheet of reflective
laminate having an upper reflective layer, a first polymeric layer bonded to
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the upper reflective layer, a cellular layer bonded to the first polymeric
layer,
a second polymeric layer bonded to the cellular layer and a bottom reflective
layer bonded to the second polymeric layer, to have a base, a first sidewall
and a second sidewall; rotating the first sidewall about a first bend line to
dispose the first sidewall inclined relative to the base; rotating the second
sidewall about a second bend line to dispose the second sidewall inclined
relative to the base; joining a portion of the rotated first sidewall and a
portion of the rotated second sidewall to form an assembly including the
base, the first sidewall and the second sidewall; and collapsing the assembly
to dispose a majority of the first sidewall, a majority of the second sidewall
and a majority of the base in a parallel orientation, wherein at least a
portion
of one of the first and the second sidewall overlies a portion of the base.
[0030] The method can also include cutting a layer of the reflective
laminate along one of the first bend line and the second bend line.
[0031] In a further configuration, an insulated HVAC duct component is
provided having a transition box having at least four sidewalls, a back wall,
and a front wall having a first access port, wherein at least a portion of the
back wall is formed of a duct board; a mineral wool layer having a first R
value, the mineral wool layer adjacent one of an inside surface and an outside
of the transition box; and a reflective laminate layer having a second R
value,
the reflective laminate layer located at one of inside the transition box and
outside the transition box.
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[0032] In this configuration, it is contemplated the duct board portion of
the back wall includes a second access port fluidly connected to the first
access port. It is also understood the mineral wool layer can be intermediate
the reflective laminate layer and the back wall.
[0033] An additional method is provided including locating a reflective
laminate about an HVAC component, the HVAC component at least partially
formed by duct board; and cutting an access port through a portion of the
duct board and the reflective laminate.
[0034] In a further configuration, an insulating assembly is provided,
wherein the assembly has a reflective laminate body including a first pair of
opposing sidewalls extending from a base and a second pair of opposing
sidewalls extending from the base with each of the sidewalls terminating at a
free edge. The base and the sidewalls are moveable between a first transport
position wherein a majority of the base and a majority of the sidewalls are
parallel and an installation configuration wherein the sidewalls are
perpendicular to the base. The reflective laminate includes an upper
reflective layer, a bottom reflective layer and a cellular layer intermediate
the
upper reflective layer and the bottom reflective layer. It is further
contemplated the
Date Recue/Date Received 2022-09-02
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0035] FIG. 1 is a perspective view of a register box without layers of
insulation.
[0036] FIG. 2 is a perspective view of one configuration illustrating a
first
insulation layer located along an inside surface of the register box and a
second insulation layer located along an outside surface of the register box.
[0037] FIG. 3 is a perspective view of another configuration showing the
first insulation layer located along the inside surface of the register box
and
the second insulation layer overlying the first insulation layer.
[0038] FIG. 4 is an exploded schematic view of the reflective laminate layer.
[0039] FIG. 5 is an exploded schematic view of an alternative construction
of the reflective laminate insulation layer.
[0040] FIG. 6 is a cross sectional view of the register box taken generally
along line 6-6 in FIG. 2 illustrating the first insulation layer located along
the
inside surface of the register box and the second insulation layer located
along the surface of the register box.
[0041] FIG. 7 is a cross sectional view of the register box taken generally
along line 7-7 in FIG. 3 illustrating the first insulation layer located along
the
outside surface of the register box and the second insulation layer overlying
the first insulation layer.
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[0042] FIG. 8 is a perspective view of components of the insulated register
box showing the first and second insulation layers configured to be inserted
into a register box.
[0043] FIG. 9 is a front view of the second insulation layer configured to be
inserted into a register box.
[0044] FIG. 10 is a perspective view of components of the insulated register
box showing a configuration of the first and second insulation layers
configured to be inserted into a register box.
[0045] FIG. 11 is a plan view of a cut out of a reflective laminate showing
the components prior to folding and bonding to form the insulating
assembly.
[0046] FIG. 12 is perspective view of the reflective laminate cut out of
FIG.
11 forming an insulating assembly having a base and sidewalls inclined
relative to the base.
[0047] FIG. 13 is representative cross sectional view of the insulating
assembly of FIG. 12 in a folded or transport configuration.
[0048] FIG. 14 in a top plan view of the insulating assembly of FIG. 12 in
the folded or transportation configuration.
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DETAILED DESCRIPTION OF THE INVENTION
[0049] At the outset, it should be appreciated that the use of the same
reference number throughout the several figures designates a like or similar
element.
[0050] Referring to the Figures, an insulated HVAC duct component 10
includes an HVAC transition box 20, a mineral wool layer 50, and a reflective
laminate layer 60. The HVAC transition box 20 (or transition box) includes
fittings, collars, takeoffs, register boxes, boxes, boots, stacks, register
boots,
stackheads, reducers, elbows, caps and plenums. In one configuration, the
transition box 20 includes sidewalls 22, 24, 26, 28, a back wall 30, and a
front wall 32. The transition box 20 further includes an inside surface 34 and
an outside surface 36, two access ports 38, 40 having different cross
sections. In one configuration, the transition box 20 includes a rectangular
access port 38 having a rectangular outlet framed by a depending rectangular
lip 44 that is dimensioned for a snug sliding fit within the rectangular
outlet.
The lip 44 is spaced from the adjacent sidewall 22, 24, 26, 28 of the
transition box 20 by a given fixed distance. Typical spacing between the lip
44 and the adjacent sidewall 22, 24, 26, 28 is less than approximately one
inch, and can be as little as half an inch. The transition box 20 can further
include a circular access port 40 having a circular inlet and a collar 48.
[0051] The rectangular outlet is dimensioned for registration with a diffuser
(not illustrated). The circular inlet or access port 40 typically has an inner
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Date Recue/Date Received 2022-09-02
diameter of 7 1/8 inches and forms an opening for receiving pressurized air
conducted through a branch conduit of a HVAC system.
[0052] A first insulation layer, such as the mineral wool layer SO, having a
first R value and a first thickness is located along an inside surface 34 of
the
transition box 20 as shown in FIGs. 2, 3, 6, and 7. The mineral wool layer 50
has a thickness no greater than the spacing between the lip 44 and the
adjacent sidewall, and is thus less than one inch. In most prior constructions
the thickness of the mineral wool layer 50 is between one and three-quarters
inch.
[0053] In one configuration, the second insulation layer, such as the
reflective laminate layer 60, is adjacent the outside surface of the
transition
box 20, as shown in FIGs. 2 and 6 and as described in more detail infra. In
another configuration, the second insulation layer 60 overlies the first
insulation layer, such as the mineral wool layer 50, inside the transition box
as shown in FIGs. 3 and 7.
[0054] The second insulation layer can be a reflective laminate having an
air impervious surface, a second R value and a second thickness, wherein the
second thickness is different from the first thickness. In the overlaying
construction of the two layers of insulation, the layers form a composite that
can be unbonded or bonded. Thus, a bonding layer 80 may be included
between the first insulation layer 50 and the second insulation layer 60, such
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Date Recue/Date Received 2022-09-02
as the mineral wool layer 50 and the reflective laminate layer 60. In one
configuration, the bonding layer 80 operably bonds the second insulation
layer 60 to the first insulation layer 50 to form a bonded composite 100. The
bonding of the second (reflective) insulation layer 60 and the first (mineral
wool) insulation layer 50 is such that no intermediate gap is formed between
the layers of the composite. That is, the second insulation layer 60 is
contiguous with the mineral wool insulation layer (first insulation layer) 50.
The bonding of the second insulation layer 60 and the first insulation layer
50
can be formed by a variety of adhesives, such as the water soluble adhesives.
In one construction, the adhesive partially penetrates the mineral wool fibers
and thus forms an integral bond between the first mineral wool layer 50 and
the (second) reflective laminate layer 60. Thus, no additional air gaps are
formed by the bonding layer 80 between the mineral wool layer 50 and the
reflective laminate layer 60. It is further contemplated that the adhesive can
be selected such that the bonding layer 80 increases the rigidity of the
composite 100. That is, the bonded composite 100 can be self-supporting.
[0055] For purposes of this disclosure, the mineral wool layer 50 is a low
density nonwoven fiber formed into a layer, wherein the fibers are made from
minerals or metal oxides, and can be synthetic or natural. Typically, man
made mineral fibers (MMMF) generally refer to synthetic materials. This
includes fiberglass, ceramic fibers and rock wool, also known as stone wool.
The mineral wool layer 50 can include organic fibers such as polymeric fibers
Date Recue/Date Received 2022-09-02
or inorganic fibers such as rotary glass fibers, textile glass fibers,
stonewool
(also known as rockwool) or a combination thereof. Mineral fibers, such as
glass fibers, have been found satisfactory.
[0056] The mineral wool layer SO, sometimes referred to as a batt or
blanket insulation generally spans densities in the range of about 0.5-7
lb/ft3
(8-112 kg/m3) and preferably about 1-4 lb/ft 3 (16-64 kg/m3), and more
preferably 0.3 to 1.5 lb/ft 3 (4.8-24 kg/m3). The mineral wool layer SO is
usually provided in continuous sheeting that is sometimes cut to preselected
lengths, thus forming batts. The thickness of the mineral wool layer SO is
generally proportional to the insulated effectiveness or "R value" of the
insulation.
[0057] The R value is a commercial unit used to measure the effectiveness
of thermal insulation. That is, the R value is a measure of the capacity of a
material, such as insulation, to impede thermal flow, with increasing values
indicating a greater capacity. Thermal conductance of a material is
measured, in traditional units, in BTUs of energy conducted times inches of
thickness per hour of time per square foot of area per Fahrenheit degree of
temperature difference between the two sides of the material. The R value of
the insulator is defined to be 1 divided by the thermal conductance per inch.
This means R value is an abbreviation for the complex unit combination
hr=ft2. F/Btu. In SI units, an R value of] equals 0.17611 square meter
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Date Recue/Date Received 2022-09-02
AT = A = t
kelvins per watt (m2.K/W). As defined R value is Rvalue= __________________
where A is
HeatLoss
the temperature difference in degrees Fahrenheit, A is the area in square
feet,
t is the time in hours, and HeatLoss is the heat loss in BTUs. Typical R
values
for the mineral wool layer SO is between approximately 3.1 /inch to 4.3/inch
thickness of the layer.
[0058] In some embodiments, a vapor retarder facing layer 52, which may
be a cellulosic paper, typically formed from Kraft paper, coated with a
bituminous adhesive material, such as asphalt, or polymeric film, such as
LDPE (low density polyethylene), is provided on one major surface of the
mineral wool layer 50. The facing layer and bituminous layer together form
bitumen-coated Kraft paper.
[0059] The second or reflective laminate layer 60 is a laminate that includes
an upper reflective layer 62, a lower reflective layer 66 and an intermediate
cellular layer 64.
[0060] In one construction, the cellular layer 64 is comprised of a multitude
of closed cells. While the cellular layer 64 can be formed of open cells, as
the
closed cells provide enhanced resistance to thermal flow, the closed cell
structure has been found satisfactory. The closed cells of the cellular layer
62 can be formed from a foamed polymer including thermoplastics,
thermosets or thermoplastic elastomers, as is well known. Alternatively, the
cellular layer 62 can be formed of a multitude of sealed pockets, each
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Date Recue/Date Received 2022-09-02
retaining a volume of air or other gas. The cellular layer 62 can have any of
a
variety of thickness, such as but not limited to 3/16 inch to one half inch.
[0061] The pockets of the cellular layer 64 can be in form of a layer of
discrete bubbles, or multiple layers of bubbles as defined by a polymer. The
discrete bubbles can be as small as 1/10 inch in diameter, to as large as an
inch or more. In addition, the volume of gas retained within the bubble can
be controlled to provide differing degrees of thermal protection or control
the
resulting thickness of the cellular layer. That is, the bubble may be under a
positive pressure, rather than merely retaining a volume of gas.
[0062] In one configuration, the reflective laminate 60 can include at
least
five layers - the upper and lower reflective layers 62, 66, a polymer layer
68,
70 adjacent each reflective layer 62, 66, wherein each polymer layer is
selected to increase strength of the laminate and the cellular layer 64
intermediate the two polymer layers. Polyethylene has been found a
satisfactory polymer for the polymer layer. Thus, for example, each reflective
layer 62, 66 can be bonded to a polyethylene layer 68, 70, wherein the
polyethylene layers sandwich the cellular layer 64 therebetween.
Alternatively, the reflective laminate 60 can be formed with three layers -
the
upper reflective layer, the lower reflective layer and the intermediate
cellular
layer, wherein the upper and lower layers sandwich the cellular layer and a
bonding such as adhesive or ultrasonic welding joins the layers together.
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Date Recue/Date Received 2022-09-02
[0063] In a further construction, the reflective laminate (or second
insulation layer 60) can include two cellular layers 64, 74, wherein the two
cellular layers are connected by an intermediate polymer layer 72, such as a
polyethylene layer. Thus, the second insulation layer 60 can have the five
layer construction including (i) the upper reflective layer 62, (ii) the
polymeric
layer 68, (iii) the cellular layer 64, (iv) the polymer layer 70, and (v) the
lower
reflective layer 66, or the seven layer construction including (i) the upper
reflective layer 62, (ii) the polymer layer 68, (iii) the cellular layer 64,
(iv) the
polymer layer 72, (v) the cellular layer 74, (vi) the polymer layer 70, and
(vii)
the lower reflective layer 66.
[0064] A satisfactory reflective laminate 60, as the second insulation layer,
is a foil/bubble reflective insulation marketed by Reflectix, Inc of
Markleville
Indiana under the mark Reflectix , including either the single bubble or
double bubble product.
[0065] In one construction, the second insulation layer 60 is the Reflectix
double bubble product having a nominal thickness of 5/16 inch and an R
value of approximately 4.2. In this construction, the mineral wool layer SO
has a thickness of one inch and an R value of approximately 4 to 4.2, and the
R value of the resulting composite 100 is approximately 8, and has a
thickness of approximately 1 5/16 inch. Thus, the two layers of insulation
are of different materials and different thickness.
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Date Recue/Date Received 2022-09-02
[0066] In contrast, as set forth by Reflectix publications, if the
Reflectix
product (second insulation layer 60) is simply doubled (that is two Reflectix
reflective laminate 60 layers are directly bonded together), the resulting
construction has an R value of approximately 5.3, rather than the expected
8.4 of the combined R values. Thus, merely doubling the reflective laminate
layer 60 does not provide the desired R value. Further, pursuant to Reflectix
company literature, a 3/4 inch air space is recommended on each side of the
second insulation layer 60. Such spacing thus requires a 1 13/16 wide gap
thereby limiting installation of the composite 100. Alternatively, if the
mineral wool layer 50 were used to obtain an R value of 8, the mineral wool
layer 50 would have a thickness of approximately two inches.
[0067] The composite of the first insulation layer (the mineral wool layer)
50, and the second insulation layer (the reflective laminate layer) 60, can be
constructed such that the R value of the composite 100 is greater than, less
than or equal to the R value of the mineral wool layer 50. Further, the R
value
of the composite 100 is at least 80% of the sum of the first R value and the
second R value. In certain constructions, the R value of the composite is at
least 90% and can be 95% of the sum of the R value for the reflective laminate
and the R value of the mineral wool layer. For example, as the reflective
laminate layer as the second insulation layer 60 has an R value of
approximately 4.2 and the first insulation layer as the mineral wool layer 50
has an R value of approximately 4.2, the composite 100 has an R value of at
Date Recue/Date Received 2022-09-02
least approximately 80% of an 8.4 R value and in selected constructions an R
value of at least 90% of the added R value of the second insulation layer (the
reflective laminate layer) 60 and the first insulation layer (the mineral wool
insulation layer) 50.
[0068] The composite 100 can have a thickness that is less than twice the
mineral wool layer 50, yet have an R value that is substantially equal to
twice
the R value of the mineral wool layer 50. For example, the reflective laminate
can have an R value of 4 with a 5/16 inch thickness and the mineral wool
layer can have an R value of 4 with a one inch thickness, the resulting
composite 100 (bonded or unbonded) having an R value of 8 and a thickness
of 1 5/16 inch. As two directly bonded reflective laminates, (if bonded
together without intermediate air gap) exhibit an R value of approximately
5.3 (4.2 + 1.1), the composite 100 has an R value that is greater than the R
value of bonded reflective laminate layers.
[0069] It is understood the composite 100 can be formed with variety of
thicknesses of the mineral wool layer 50. For example, if the mineral wool
layer 50 is sized to provide an R value of 6, then the resulting composite 100
has an R value of approximately 10.
[0070] Conversely, the second insulation layer 60 can be used in
combination with a relatively thin mineral wool layer 50, such as one having a
R value of 2 (7/16 inch thick). Thus the R value 4 of the second insulation
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Date Recue/Date Received 2022-09-02
layer 60 provides a composite 100 having an R value of approximately 6 with
a thickness of 3A inch in contrast to a thickness of 1.5 inches in prior
constructions.
[0071] Although the first insulation layer is set forth as the mineral wool
layer and the second insulation layer is set forth as the reflective laminate
layer, it is understood the first insulation layer and the second reflective
laminate layer can be any two different insulation materials, with or without
an air gap, wherein the air gap is within one of the layers or formed between
the two layers.
[0072] That is, the composite 100 is formed of two different insulation
materials, wherein one or each of the insulation materials can be a single
material or layer or laminate.
[0073] As the present construction provides for comparable R values at
reduced thickness (as compared to prior constructions) the HVAC
components to be insulated by the present construction can be of standard or
reduced size, thereby reducing material costs. Further, reduced sizing allows
installation in previously inaccessible locations.
[0074] It is contemplated that the insulated HVAC duct component 10 can
be any type of duct component used in an HVAC system where insulation is
desired. Without limiting the scope of disclosure, the first and second
insulation layers 50, 60 are set forth in terms of operable connection with
the
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ducts 10 in the configuration of a transition box 20, including but not
limited
to a register box, plenum box, ceiling box, register boot, stack boot, box,
boot, stack, and stackhead. Register boxes 20 are employed to distribute a
pressurized air flow from a main or trunk duct to a room interface. As the
register box 20 is located at the exposure to a room, the register box is
typically located in areas of limited spacing. That is, the register box 20
typically must conform to a given size limitation.
[0075] Referring to Fig. 1, the register or air distribution box 20 is
constructed of sheet-metal, such as galvanized 30-gauge steel panels
forming sidewalls 22, 24, 26, 28, the back wall 30, front wall 32, and an
outer flange 18. In one configuration, the sidewalls 22, 24, 26, 28 are
constructed from a single blank of galvanized sheet metal steel. Opposing
sidewalls 22, 26 and 24, 28 and the back wall 30 include flange portions that
are folded over the sidewalls and are staked together to form a mechanically
stable unit. When assembled and connected together, the sidewalls 22, 24,
26, 28, the front wall 32 and the back wall 30 provide boundaries for an air
distribution chamber of the register box 20. For the exemplary embodiment
shown in Figure 1, the register box 20 dimensions are 14 inches by 3 1/2
inches by 8 inches. The front wall 32 may also include vents 16 for venting
the insulation layers 50 and/or 60.
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Date Recue/Date Received 2022-09-02
[0076] Although the HVAC component is described in terms of a metal
construction, it is understood that a variety of materials can be used to for
the component, such as laminates, plastics and alloys.
[0077] Thermal insulation, in the form of the composite 100 (bonded or
unbonded) or the mineral wool layer 50 on one side of the box and the
reflective laminate layer on the other side, is added to the internal surfaces
of
the sidewalls of the register box to prevent heat transfer and for noise
reduction purposes. However, as the footprint of the register box 20 is
limited and the relative size of the air passageways must be maintained, the
available space for insulation is restricted.
[0078] The present insulation layers 50, 60 can be disposed within the
available standard spacing in an existing register box 20 as shown in FIGs. 3
and 7, yet provide enhanced R value such as R8.
[0079] The first and second insulation layers 50, 60 can be disposed within
the register box 20 so that the exposed surface of the second insulation layer
(the reflective laminate) 60 contacts the air flow through the register box
20.
Thus, the reflective layer of the reflective laminate defines the surface of
insulation that is exposed to the air flow through the HVAC duct and reduces
the entrainment of the underlying mineral wool layer 50 in the air flow. This
improves indoor air quality. In this configuration, as shown in FIG. 8, the
insulation layers 50, 60 includes a base piece 90 sized to overlap the back
24
Date Recue/Date Received 2022-09-02
wall 30 of the register box 20, two pieces 92, 94 sized to overlap two
opposing sidewalls 22, 26 and two pieces 96, 98 sized to overlap two
opposing sidewalls 24, 28 of the register box 20. The base piece 90 includes
an aperture 104 for receiving the collar 48 of the register box 20. For the
exemplary embodiment shown in Figure 1, wherein the register box 20
dimensions are 14 inches by 3 1/2 inches by 8 inches, the base piece 90
sized to overlap the back wall is about 12 inches by 8 inches, two of the
sidewall pieces 92, 94 are about 12 by 3 Y2 inches and two of the sidewall
pieces 96, 98 are about 8 inches by 31/2 inches. In an alternative
configuration, as shown in FIG. 9, the first and second insulation layers SO,
60 include a base piece 91 sized to overlap the back wall 30 and the two
opposing sidewalls 22, 26 of the register box 20 and side pieces 92, 94
sized to overlap the other two opposing sidewalls 24, 28. That is, the base
piece 91 is about 15 inches by 12 inches and the side pieces 92, 94 are each
about 8 inches by 3 Y2 inches.
[0080] As shown in FIG. 10, the reflective laminate 60 may include a single
piece blank of reflective laminate 60 having four base forming fold lines 112,
114, 116, 118, a base 119, and four side flaps (sidewalls) 122, 124, 126,
128. The four side flaps 120, 122, 124, 126 are typically formed by
removing corner portions of the reflective laminate and bending the flaps
122, 124, 126, 128 along the base forming fold lines 112, 114, 116, 118.
The second insulation layer 60 typically includes a die-cut aperture 106 for
Date Recue/Date Received 2022-09-02
receiving the collar 48, although it should be appreciated by those having
ordinary skill in the art that other methods may be used to form the aperture
in the second insulation layer. For the exemplary embodiment shown in
Figure 1, wherein the transition box 20 dimensions are 14 inches by 3 1/2
inches by 8 inches, the reflective laminate layer 60 has the following
dimensions: the base measures about 12 inches by 8 inches and each flap
measures about 8 inches by 3 1/2 inches.
[0081] Thus, a self-supporting reflective laminate 60 forming an insulating
assembly 160 is formed by folding each of the side flaps (sidewalls) 120, 122,
124 and 126 about the respective fold line and joining the abutting edges or
corresponding portions of the sidewalls to form (or retain) the sidewalls
generally perpendicular to the base 119. Fasteners, including but not limited
to tape, staples, stitching, bonding, ultrasonic welding or adhesives can be
used affix abutting side flaps to each other. Fasteners includes mechanical
fasteners such as staples, rivets, barbs, darts, clips.
[0082] In a further configuration, the sidewalls 120, 122, 124 and 126 can
include mating tabs and slots, wherein the tab or tabs of one sidewall are
received into corresponding slots 129 on an adjacent sidewall to engage the
walls and dispose the laminate in a self-supporting orientation, such as the
insulating assembly 160. In this configuration, no mechanical fasteners are
required to retain the insulating assembly 160 in the operable orientation.
26
Date Recue/Date Received 2022-09-02
That is, a substantially self supporting orientation able to retain the
assembly
in the operable configuration.
[0083] The fold lines, such as fold lines 112, 114, 116, 118, can include a
line of weakness such as a score, perforation or even stressed section of
material. The line of weakness can be used to promote folding of the
respective wall or relative to the base. As set forth herein, the remaining
material along the fold line forms a hinge about which the respective
components of the insulating assembly 160 can pivot for transition from a
storage/shipping configuration to use or installation configuration.
[0084] It is further understood, the line of weakness can be sufficient depth
or fracture of material of the reflective laminate 60 to permit a separation
of
the material along the line. That is, the line of weakness can render the
laminate 60 sufficiently frangible that the material can be separated into
distinct pieces. This allows for an installer to remove an area of material
from the laminate 60 (or assembly 160), such as a vent hole, during
installation, without requiring the use of separate tools or knives. That is,
the
installer merely applies a tearing or rendering force along the lines of
weakness and the portions of the reflective laminate 60 (or assembly 160) are
separated.
[0085] Referring to FIGs 10 -13, the reflective laminate layer 60 can be thus
formed into the self-supporting reflective laminate body or insulating
27
Date Recue/Date Received 2022-09-02
assembly 160 having the base 119 and the four extending sidewalls 122,
124, 126 and 128, wherein the sidewalls are at least substantially
perpendicular to the base. Longer sidewalls 122, 126 can each include two
collapsing fold lines 127. The collapsing fold line 127 extends from the
junction of the base 119, the longer opposing sidewall 122, 126 and one of
the shorter sidewalls 124, 128 at an approximate 45 degree angle to the free
edge of the longer sidewall. The collapsing fold lines 127 form triangular
portions in the longer of the sidewalls, such that as the short sidewalls 124,
128 are folded about fold lines 116, 112 respectively, toward each other, the
longer sidewalls 122, 126 rotate towards each other about respective fold
lines 114, 118 and the triangular portions fold about the adjacent collapsing
fold line 127 until the base 119, the shorter sidewalls 124, 128, the
triangular portions and the remaining portions of the longer sidewalls 122,
126 are parallel as seen in FIG. 13. The resulting collapsed structure has a
thickness of 4 layers of the reflective laminate 60.
[0086]
In addition, as seen in FIG. lithe sidewalls 122 and 126 can include
projecting tabs 122', 122" and 126' and 126" respectively, wherein the
projecting tabs are folded to overlay a portion of the adjacent sidewall and
fastened to that sidewall, such as by staples, adhesives, stitching or bonding
to form the self-supporting assembly.
[0087] As set forth above, the tabs 122', 122" and 126' and 126" can be
configured to be received in corresponding slots 129 (shown in Figure 11) in
28
Date Recue/Date Received 2022-09-02
the adjacent sidewall to operably engage the sidewalls, such as in the open
orientation.
[0088] As in the alternative construction, the longer sidewalls 122, 126 can
include collapsing fold lines 127 and the joined sidewalls 124, 128 can be
folded about the respective fold lines and the respective sidewalls folded
about the collapsing fold lines such that a majority of the sidewalls are
parallel to a majority of the base 119 and the sidewalls generally overlie the
base.
[0089] Thus, the insulating assembly 160 can be compactly configured for
efficient shipment and storage. In the shipping or storage configuration, the
sidewalls or flaps 120, 122, 124 and 126 or portions are folded about the
respective fold lines 112, 114, 116, 118 so that the sidewalls are
substantially parallel to each other as well as the base 119. Further, in one
configuration, the folded sidewalls 120, 122, 124 and 126 are within the
footprint (or periphery) of the base 119. In response to customer need for an
existing HVAC duct component to have increase R value or a retailer wishing
to offer a line of such components having increased R value, the insulating
assembly 160 can be unfolded to assume the self-supporting configuration,
wherein the sidewalls 122, 124, 126, 128 are generally perpendicular to the
base 119.
29
Date Recue/Date Received 2022-09-02
[0090] To transition the insulating assembly 160 from the transport
configuration to the installation configuration, the sidewalls 122, 124, 126,
128 rotate about the respective fold lines until the sidewalls are
perpendicular to the base 119, and the assembly is self-supporting. The
opened insulating assembly 160 can then be slid over the outside surface of
the HVAC component or tucked within the HVAC component, depending on
the intended operation.
[0091] Thus, a collapsible insulating assembly 160 for HVAC ductwork is
provided, wherein the assembly can be disposed in a transport configuration,
wherein the walls or portions are folded about fold lines to be at least
substantially parallel with each other and the base 119 and an operative
configuration, wherein the opened insulating component encompasses a
portion or is encompassed by a portion of a HVAC ductwork.
[0092] It is contemplated that one layer of the reflective laminate 60 can be
scored or actually cut along the desired fold lines 112, 114, 116, 118, such
as each fold line or alternating fold lines, thereby reducing the effective
radius of curvature of the bend. In one configuration, the cut (or score) is
formed along the outside surface of the respective fold line] 12, 114, 116,
118, that is the surface of the laminate experiencing the greater radius of
curvature. It is contemplated the fold lines 112, 114, 116, 118 for one, a
pair
or all the sidewalls can be scored to provide the reduced bending
deformation and assist in disposing the insulating assembly 160 in the
Date Recue/Date Received 2022-09-02
transport configuration. Thus, the remaining thickness of the reflective
laminate 60 forms a hinge about which the sidewall can pivot relative to the
base 119.
[0093] To incorporate both insulation layers 50, 60 into the register box
20, the mineral wool (layer) SO is located along the inside surface 34 of the
register box 20. The perimeter edges of the mineral wool layer SO engage
the lip 44 of the register box 20 to secure the mineral wool layer SO in
place.
The second insulation layer 60 (the reflective laminate layer) is then placed
along the top (exposed) surface of the mineral wool, wherein a perimeter
edge of the second insulation layer 60 engages the lip 44 of the register box
20 securing the second insulation layer in place. In one configuration, an
adhesive as described supra is placed between the mineral wool layer 50 and
the reflective laminate layer 60 to provide the bonded composite 100.
Alternatively, the second insulation layer can be located against the mineral
wool, and retained in place by a slight compressive force from the lip 44 and
the adjacent sidewall. The combined thickness of the mineral wool layer 50
and the reflective laminate layer 60 (and hence composite 100) is less than
two inches, and in selected configurations, less than approximately 1 inch,
depending on the specific configuration of the transition box.
[0094] Thus, as the second insulation layer 60 is in contact with the
passing air flow in the register box 20, there is no exposed mineral wool to
31
Date Recue/Date Received 2022-09-02
the air flow through the register box 20. Therefore, less mineral wool is
entrained in the passing air flow, and indoor air quality is improved.
[0095] In another configuration, the mineral wool layer 50 is disposed
within the existing register box 20 and the second insulation layer 60 (the
reflective laminate) is disposed on the outside of the register box 20 as
shown in FIGs. 2 and 6. The mineral wool layer 50 can be inserted into the
register box 20, for example, as described in supra. For the exemplary
embodiment shown in Figure 1, the second insulation layer 60 overlies the
outside surface 36 of the sidewalls 22, 24, 26, 28 and back wall 30 of the
register box 20. The second insulation layer 60 further includes triangular
tabs 138 located at each corner of the sidewalls 22, 24, 26, 28, wherein each
triangular tab 138 lies flat along a portion of the second insulation layer
60.
In one configuration, two triangular tabs 138 overlie one sidewall 22 and two
triangular tabs overlie the opposing sidewall 26. The triangular tabs 138 are
secured to the register box 20 by fasteners 140. Fasteners 140 can include,
but are not limited to, pins, adhesives, screws, staples and nails. In another
configuration, the triangular tabs 138 are secured to the second insulation
layer 60. For example, triangular tabs 138 can be fastened and/or adhered
to the surface of the second insulation layer 60. In a further configuration,
selected sidewalls can include an integral tab sized to overlie a portion of
the
an adjacent sidewall (in the operable configuration) wherein the tab is
secured to the adjacent sidewall by any of the previously listed fasteners.
32
Date Recue/Date Received 2022-09-02
[0096] In both configurations, the enhanced insulation capacity of the
present invention reduces energy costs as well as increases useful life of the
register box.
[0097] Thus, the reflective laminate body 160 can be sized fit within the
transition box 20 or slide over the outside surface of the transition box. For
either configuration, the sizing of the reflective laminate body 160 can be
selected to provide a friction fit or retention, or cooperate with fasteners
including mechanical fasteners or adhesives, such as adhesive layer 170.
[0098] In
a further configuration, the insulating assembly 160 is shipped in
the shipping configuration, with the base 119 and sidewalls 120, 122, 124
and 126 being substantially parallel. In use, the insulating assembly 160 is
transitioned to the installation configuration and engaged with the HVAC
component, such as the transition box 20. The insulating assembly 160 can
be engaged directly to the transition box 20 on either the inside surface 34,
the outside surface 36 or if two insulating assemblies are employed, both the
inside surface and the outside surface.
[0099] The resulting construction includes the transition box 20 having the
reflective laminate 60 insulating assembly 160 in a thermal barrier
engagement relative to the inside surface 34, the outside surface 36 or both
the inside surface and the outside surface of the transition box 20 - wherein
additional insulation layers of different material can be located intermediate
33
Date Recue/Date Received 2022-09-02
the insulating component and the transition box or the additional insulation
layers can be engaged to locate the insulating assembly intermediate the
respective surface of the transition box and the additional insulation layer.
[00100] The use of the prefabricated insulating assembly 160 gives the
installer the flexibility to use one or two of the assemblies with or without
additional insulating layers, such as the batten or wool. The insulating
assemblies 160 can be located relative to the transition box 20 with one on
the inside surface, one on the outside surface or both on either the inside
surface or the outside surface of the transition box- with or without
additional layers of different insulation, wherein the additional layers of
insulation can be exterior to the insulating assembly 160 or intermediate the
insulating assembly and the transition box.
[00101] A retailer could inventory a transition box 20 of a given dimension
having the layer of mineral wool on the inside surface providing an R value of
approximately 4. By virtue of the present disclosure, the reflective laminate
assembly 160 can be selectively located on the inside or the outside of the
transition box, thereby increasing the effective R value of the transition box
to 6, or 8 or more, depending on the thickness of the reflective laminate (the
reflective laminate assembly).
[00102] In an alternative configuration, at least the back wall 30 of the
transition box 20 can be formed of duct board. Satisfactory duct boards
34
Date Recue/Date Received 2022-09-02
include those by johns Manville, Owens Corning as well as CertainTeed Saint-
Gobain. The duct board is able to be readily cut by commercially available
knives. Thus, the transition box 20 can be formed with only a single access
port, the large access port 38, wherein the transition box includes the
insulation and reflective laminate 60 as in the configurations set forth
above.
It is understood, the insulating assembly 160 can be constructed to be
without apertures (other than the main opening of the box), such that the
installer can form the necessary specific ports for installation. Also, the
insulating assembly 160 can include the lines of weakness for preferential
separation of portions of the assembly to match the corresponding transition
box 20.
[00103] The installer on-site then uses the commercially available knife and
forms an access port in the back wall 30 as dictated by the on-site
construction. The formed access port extends though the insulating material
as well as the duct board. Thus, the installer can form any of a variety of
access ports such as a circular access port, wherein a separate tab collar, as
known in the art, can be used to interconnect the transition box to the on-
site duct. This configuration of the transition box 20 including a duct board
wall (or portion of the wall), provides for the installer on-site to customize
the transition box, without sacrificing the thermal performance of the
transition box.
Date Recue/Date Received 2022-09-02
[00104] It is contemplated that one, two or more walls of the transition box
can be partly or completely formed of the duct board. In one configuration,
the entire transition box is formed of duct board, thereby allowing the on-
site installer to fully customize the transition box to the on-site
construction.
As the insulating assembly 160 can be assume an open configuration
corresponding to the transition box 20, the installer can simultaneously
modify the transition box and the insulating assembly on site to
accommodate unique (or even standard) configurations.
[00105] Thus, by locating the insulating assembly 160 (without having any
preformed apertures or ports in the base or sidewalls) about the HVAC
component, such as the transition box 20, the installer can then custom cut
the duct board and the adjacent portion of the insulating assembly to form a
matching construction of the HVAC component and the insulating assembly.
That is, by cutting the duct board of the HVAC component and the insulating
assembly 160 substantially simultaneously (while they are operably aligned),
the resulting fit between the HVAC component and the insulating assembly is
ensured.
[00106] The insulating assembly 160 can be used in conjunction with any
other insulating material, wherein the ordering (layering) of the materials
relative to the environmental temperature gradient can be in any order.
36
Date Recue/Date Received 2022-09-02
[00107] In a further configuration, as seen in Figures 11, 12 and 13, the
reflective laminate 60 and insulating assembly 160 can include a layer of
adhesive 170. The adhesive layer 170 can be substantially uniform across
the area of the reflective laminate 60 or the insulating assembly 160.
Alternatively, the adhesive layer 170 can be applied in a pattern either to
reduce the amount of adhesive used or in a predetermined pattern to
accomplish a function such as bonding to a portion of the transition box 20
or another layer of insulation upon engagement.
[00108] The adhesive layer 170 is shown in predetermined areas on the flaps
in Figure 11. It is understood the predetermined areas can be on any portion
of the assembly 160 for either retaining the assembly in the operating
orientation or bonding the assembly to the HVAC component. For example,
the adhesive layer 170 can be applied on a majority of an inside or outside
surface of the insulating assembly 160, such that upon operable installation
of the assembly with the HVAC component, the adhesive layer (if on the
inside of the assembly) retains the assembly relative to the outside of the
HVAC component or additional insulating layer, if present, on the outside of
the HVAC component and the adhesive layer (if on the outside of the
assembly) retains the assembly relative to the inside of the HVAC component,
or additional insulating layer, if present, on the inside of the HVAC
component.
37
Date Recue/Date Received 2022-09-02
[00109] The adhesive can be a tape or contact adhesive with or without a
removable backing layer 172. In use, the installer configures the reflective
laminate 60 or insulating assembly 160 in the operable configuration
(removes the backing layer 172, if employed) and presses the reflective
laminate or insulating assembly into engagement, wherein the adhesive
retains the laminate or assembly is operably retained. As seen in Figure 12, a
representative sidewall 128 includes the adhesive layer 170. Referring to
Figure 13, the adhesive layer 170 is shown (in exaggerated thickness) on
sidewalls 124 and 128, wherein the backing layer 172 is shown in a partially
peeled configuration relative to sidewall 124.
[00110] The adhesive can be a tape such as 3M Double Coated Tapes or
contact adhesive as known in the art, such as 3M Hi-Strength spray adhesive
or FastbondTM adhesive as well as Scotch-WeldTM adhesive.
[00111] While the invention has been described in connection with a
particular embodiment, it is not intended to limit the scope of the invention
to the particular form set forth, but on the contrary, it is intended to cover
such alternatives, modifications, and equivalents as may be included within
the spirit and scope of the invention as defined by the appended claims.
38
Date Recue/Date Received 2022-09-02
