Process for forming an insulated register box in which the register box has a improved r-value

A process for insulating a register box such that the register box has an R-value of six, register box having a plurality of side panels arranged in a generally rectangular configuration and a collar opening through a wall, the wall extending across the generally rectangular configuration, the process comprising:

• flowing an expandable closed cell polyurethane material with a temperature of between 160° F. and 180° F. toward the plurality of side panels;
• placing the register box into or onto a support structure;
• introducing a liner over the flowed expandable closed cell polyurethane material within the register box;
• placing a form onto the liner in the register box so as to shape the expandable closed cell polyurethane material within the register box;
• and
• removing the form and the liner from the register box such that the solidified expandable closed cell polyurethane material resides against the plurality of side panels and against the wall, the solidified expandable closed cell polyurethane material against the plurality of side panels having a thickness of approximately one inch.

A process for insulating a register box such as the register box has an R-value of eight, the register box having a plurality of side panels arranged in a generally rectangular configuration and a collar opening through the wall, the wall extending across the generally rectangular configuration, the process comprising:

• flowing an expandable closed cell polyurethane material at a temperature 160° F. and 180° F. toward the plurality of side panels;
• placing the register box into or onto a support structure;
• introducing a liner over the flowed expandable closed cell polyurethane material within the register box;
• placing a form onto the liner in the register box so as to shape the expandable closed cell polyurethane material within the register box;
• and
• removing the form and the liner from the register box such as the solidified expandable polyurethane material resides against the plurality of side panels and against the wall.