# US 10,309,682 B2 · Process for forming an insulated register box > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,309,682 B2 - Document ID: US10309682B2 - Status: Granted - Kind: B2 - Application number: 15/439,454 - Filed: 2017-02-22 - Published: 2017-07-06 - Granted: 2019-06-04 - Earliest claimed: 2015-03-25 - Assignees: Sterling Custom Sheet Metal, Inc. - Applicants: Sterling Custom Sheet Metal, Inc. - Inventors: Sterling Kidd Combs - Web page: https://patentgrep.com/patent/US10309682B2 ## CPC - F24F 13/0263: {Insulation for air ducts} - B29C 41/20: incorporating preformed parts or layers, e.g. moulding inserts or for coating articles - F24F 13/06: Outlets for directing or distributing air into rooms or spaces, e.g. ceiling air diffuser - F24F 13/082: {Grilles, registers or guards} - B29C 44/025: {Foaming in open moulds, followed by closing the moulds} - B29K 2075/00: Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof}, as moulding material - B29K 2105/0058: {Liquid or visquous} - B29K 2105/04: cellular or porous - B29K 2995/0015: Insulating - F24F: AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING (removing dirt or fumes from areas where they are produced B08B15/00; vertical ducts for carrying away waste gases from buildings E04F17/02; tops for chimneys or ventilating shafts, terminals for flues F23L17/02) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS ## Abstract A process for insulating a register box in which the register box has a plurality of side panels arranged in a generally rectangular configuration and a duct opening through a wall that extends across the generally rectangular configuration, in which the process includes flowing an expandable polymeric material toward the plurality of side panels, placing the register box into or onto a support structure, introducing a liner over the flowed expandable polymeric material within the register box, and placing a form onto the liner in the register box so as to shape the expandable polymeric material within the register box. The form and the liner are then removed from the register box. ## Claims ### Claim 1 A process for insulating a register box, the register box having a plurality of side panels arranged in a generally rectangular configuration and a duct opening through a wall that extends across the generally rectangular configuration, the process comprising: flowing an expandable polymeric material toward the plurality of side panels; placing the register box into or onto a support structure; introducing a liner over the flowed expandable polymeric material within the register box; placing a form onto the liner into the in the register box so as to shape the expandable polymeric material within the register box; and removing the form and the liner from the register box. ### Claim 2 (depends on 1) The process of claim 1, further comprising: closing a lid over said form and over an end of the register box so as to limit an expansion of the expandable polymeric material. ### Claim 3 (depends on 2) The process of claim 2, further comprising: locking said lid over the end of the register box for a period of time while the expandable polymeric material expands. ### Claim 4 (depends on 3) The process of claim 3, further comprising: unlocking said lid prior to the step of removing the form and the liner. ### Claim 5 (depends on 1) The process of claim 1, further comprising: positioning said support structure onto an underlying surface prior to the step of placing the register box. ### Claim 6 (depends on 1) The process of claim 1, said support structure having an interior, the step of placing the register box comprising: positioning the duct into the interior of said support structure and positioning the wall of the register box onto a top of said support structure. ### Claim 7 (depends on 1) The process of claim 1, further comprising: locking said support structure so as to be in a fixed position on the underlying surface. ### Claim 8 (depends on 1) The process of claim 1, said form being a plug having a diameter greater than a diameter of the duct, the step of placing the form comprising: placing said plug over the duct so as to be generally axially aligned with the duct such that said plug resides on the wall of the register box. ### Claim 9 (depends on 1) The process of claim 1, the step of introducing said liner comprising: introducing said liner over the flowed expandable polymeric material such that outer edges of said liner reside outwardly of an end of the register box. ### Claim 10 (depends on 9) The process of claim 9, the step of removing comprising: grasping the outer edges of the liner; and lifting said liner and said form from the register box. ### Claim 11 (depends on 10) The process of claim 10, further comprising: lifting the register box from said support structure following the step of removing. ### Claim 12 (depends on 5) The process of claim 5, said underlying surface being a carousel, the process further comprising: rotating said carousel prior to the step of removing. ### Claim 13 (depends on 1) The process of claim 1, further comprising: solidifying the flowed expandable polymeric material against the plurality of side panels. ### Claim 14 (depends on 13) The process of claim 13, the register box having a plurality of flanges extending inwardly respectively from the plurality of side panels at an end thereof opposite the wall of the register box, the plurality of flanges defining an aperture, the step of solidifying comprising: solidifying the expandable polymeric material against the plurality of side panels such that the solidified expandable polymeric material as a thickness approximately equal to a width of the flange. ### Claim 15 (depends on 13) The process of claim 13, at least one side panel of said plurality of side panels having a seam, the step of solidifying comprising: solidifying the expandable polymeric material such that a portion of the solidified expandable material emerges through the seam. ### Claim 16 (depends on 13) The process of claim 13, the wall having a seam adjacent the opening of the duct, the step of solidifying comprising: solidifying expandable polymeric material such that a portion of the solidified expandable polymeric material emerges through the seam. ### Claim 17 (depends on 13) The process of claim 13, the step of removing being after the step of solidifying. ### Claim 18 (depends on 1) The process of claim 1, the step of flowing comprising: providing a supply of the expandable polymeric material; and injecting the supply of the expandable polymeric material as a foam toward the plurality of side panels. ### Claim 19 (depends on 18) The process of claim 18, the step of injecting comprising: moving a foam gun around the interior of the register box such that the foam expandable polymeric material is directed toward the plurality of side panels.