Ceiling Duct Insert

The present Application relates to and claims priority to U.S. Provisional Patent Application, Ser. No. 63/571,022, filed on Mar. 28, 2024, entitled “Ceiling Duct Insert.” The subject matter disclosed in that Provisional Application is hereby expressly incorporated into the past Application.

The present disclosure relates to portable heating, ventilation, and air conditioning (HVAC) system ducting and, particularly, to ceiling panel inserts for use in drop ceilings that can couple to HVAC duct hoses.

A common feature of commercial interior spaces is the use of drop ceilings. A drop ceiling is a panelized ceiling structure that is typically attached to and suspended from the room ceiling. The drop ceiling provides an overhead ceiling surface while allowing space between the drop ceiling and the actual building's ceiling to accommodate, and provide easy access to, utilities such as light wiring and HVAC ducting. Many offices, data centers, and stores, including supermarkets and department stores, employ these drop ceilings.

A typical drop ceiling is composed of a metal grid that is suspended under the room ceiling. Modular panels fit within the grid to provide the ceiling surface. An advantage with drop ceilings is certain ceiling panels can be removed and replaced with lights or vents where needed in the room. Above the drop ceiling is where the wiring for the lights and ducts from the vents are located. With regard to ducts, they can extend from the vent to either the exterior or the HVAC system of the building.

An issue for some, particularly, commercial buildings. is an HVAC system's occasional failure. An HVAC system's failure in department or grocery stores, for example, may create discomfort for customers and/or damage merchandise. This is why stores often have access to portable HVAC systems that can air-condition the room (either hot or cold) to return the temperature within the indoor space to an appropriate level. A portable HVAC system may include an air handling unit that blows either cold or warm air. For example, a portable air-conditioner unit can draw in ambient air from the indoor space, pass the air through coils that cool it and dispense that cool air back into the room.

An issue with such portable air-conditioners, however, is that warm air is a byproduct generated by this cooling process. This warm air needs to be vented away from the room that is being cooled. Because heat rises, the space between the top ceiling of the building or room and the lower drop ceiling is a useful location to vent this warm air. Additionally, ducts or ducting hoses can be extended to the exterior of the building so the warm air is vented outside. In either case, a duct hose, which is a relatively large diameter tube, can be attached at one end to the exhaust of the air conditioning unit and extend up into the drop ceiling at the other end. A panel in the drop ceiling can be removed to create an opening or receive a duct insert that the duct hose can attach to for providing a passageway between the air conditioning unit and the space above the drop ceiling.

Another issue with these systems is that the duct hosing typically extends upward from the portable air conditioner to the drop ceiling. The duct hose can be secured onto a ring located on the duct insert that is fitted into the drop ceiling. However, there is a propensity for these duct hoses to disconnect from the ring and fall down. Another issue is that the duct insert has an opening to vent the warm air, but no way to attach another duct hose to the insert on the topside of the drop ceiling to continue directing the air to another location.

Accordingly, an illustrative embodiment of the present disclosure provides a ceiling duct insert that includes a panel and an opening disposed through the panel. The opening is sized to allow the warm air generated by the HVAC unit to exhaust therethrough. A ring-shaped flange extends from the underside of the panel to receive the duct hose. The outer surface of the flange has a negative angle from the panel to the lower edge of the flange, wherein the bottom of the flange has a wider diameter than the top of the flange. In such an embodiment, the bottom of the flange is distal from the underside of the panel and is directed towards the inside of the room so the duct hose can extend from the HVAC unit to the flange. The upper portion of the flange, with the narrower diameter, is located adjacent to the panel that fits into the framework of the drop ceiling. In this way, the duct hose can be tied off onto the flange, which having a wider lower end than upper end, can assist in better holding the duct hose and prevent it from falling off.

In another illustrative embodiment of the present disclosure, the ceiling duct insert may include a ring-shaped flange on each side (e.g., top and bottom) of the panel. The flanges are in fluid communication with each other so that venting air can pass through both. This allows the exhaust from the HVAC unit to travel through the connected duct hose up through the drop ceiling with the ceiling duct insert installed, pass through the opening in the ceiling duct insert, and deposit into another duct hose connected to the topside flange. It is appreciated that the topside flange may have a negative angle, as well, that creates a narrower diameter at the panel and a wider diameter distal from the panel, again, to assist in keeping the duct hose attached thereto. Alternatively, the outer surface of the topside flange can be orthogonal to the insert panel.

An illustrative embodiment of the present disclosure provides a ceiling duct insert attachable to a duct hose. The ceiling duct includes a ceiling panel with an opening disposed therethrough. A ring-shaped flange is located about a periphery of the opening, extends from a first side of the ceiling panel, and is configured to attach to the duct hose. The ring-shaped flange has an outer surface with a negative angle that extends from a proximal end of the ring-shaped flange, proximal to the ceiling panel to a distal end of the ring-shaped flange, distal from the ceiling panel. The negative angle is defined by a second diameter at the distal end of the outer surface that is wider than a first diameter at the proximal end of the outer surface, and the outer surface of the ring-shaped flange includes a ridge that extends outwardly from the ring-shaped flange.

In the above and other illustrative embodiments, the ceiling duct insert may further comprise: a second ring-shaped flange located about the periphery of the opening and extends from a second side of the ceiling panel opposite the ring-shaped flange; the second ring-shaped flange has an outer surface with a negative angle that extends from a proximal end of the second ring-shaped flange, proximal to the second side of the ceiling panel, to a distal end of the second ring-shaped flange, and distal from the second side of the ceiling panel; the negative angle on the outer surface of the second ring-shaped flange is defined by a second diameter at the distal end of the outer surface of the second ring-shaped flange that is wider than a first diameter at the proximal end of the outer surface of the second ring-shaped flange; the outer surface of the second ring-shaped flange includes a ridge that extends outwardly from the second ring-shaped flange; the second ring-shaped flange can have an outer surface oriented orthogonal to the ceiling panel; the ring-shaped flange is configured to attach to an end of the duct hose between the ridge and the proximal end of the outer surface; the second diameter at the distal end of the outer surface is between about 5.9 inches to about 23.9 inches and the first diameter at the proximal end of the outer surface is between about 5.8 inches to about 23.8 inches; the negative angle between the ceiling panel and the outer surface of the ring-shaped flange is less than 90 degrees; and the negative angle between the ceiling panel and the outer surface of the ring-shaped flange is between about 89.99 degrees to about 46 degrees.

Another illustrative embodiment of the present disclosure provides a ceiling duct insert attachable to a duct hose. The ceiling duct includes a ceiling panel with an opening disposed therethrough. The ceiling panel further includes a ring-shaped flange located about a periphery of the opening, extends from a first side of the ceiling panel, and is configured to attach to the duct hose. The ring-shaped flange has an outer surface with a negative angle that extends from a proximal end of the ring-shaped flange, proximal to the ceiling panel, to a distal end of the ring-shaped flange distal from the ceiling panel. The negative angle is defined by a second diameter at the distal end of the outer surface that is wider than a first diameter at the proximal end of the outer surface.

In the above and other illustrative embodiments, the ceiling duct insert may further comprise: a second ring-shaped flange located about the periphery of the opening and extends from a second side of the ceiling panel opposite the ring-shaped flange; the second ring-shaped flange has an outer surface with a negative angle that extends from a proximal end of the second ring-shaped flange, proximal to the second side of the ceiling panel, to a distal end of the second ring-shaped flange, and distal from the second side of the ceiling panel, wherein the negative angle on the outer surface of the second ring-shaped flange is defined by a second diameter at the distal end of the outer surface that is wider than a first diameter at the proximal end of the outer surface of the second ring-shaped flange; the second ring-shaped flange has an outer surface oriented orthogonal to the ceiling panel; the second diameter at the distal end of the outer surface is between about 5.9 inches to about 23.9 inches and the first diameter at the proximal end of the outer surface is between about 5.8 inches to about 23.8 inches; the negative angle between the ceiling panel and the outer surface of the ring-shaped flange is less than 90 degrees.

Another illustrative embodiment of the present disclosure provides a ceiling duct insert attachable to a duct hose. The ceiling duct includes a ceiling panel with an opening disposed therethrough. The ceiling panel further includes a ring-shaped flange located about a periphery of the opening, extends from a first side of the ceiling panel, and is configured to attach to the duct hose. At least a portion of the ring-shaped flange has an outer surface, and the outer surface of the ring-shaped flange has a second diameter distal from the ceiling panel that is wider than a first diameter of the outer surface of the ring-shaped flange, proximal to the ceiling panel.

In the above and other illustrative embodiments, the ceiling duct insert may further comprise: a second ring-shaped flange located about the periphery of the opening and extends from a second side of the ceiling panel opposite the ring-shaped flange; the outer surface of the ring-shaped flange includes a ridge that extends outwardly from the ring-shaped flange; and the second ring-shaped flange has an outer surface oriented orthogonal to the ceiling panel.

Additional features and advantages of the ceiling duct insert will become apparent to those skilled in the art upon consideration of the following detailed descriptions of carrying out this ceiling duct insert as presently perceived.

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates embodiments of the ceiling duct insert, and such exemplification is not to be construed as limiting the scope of the ceiling duct insert in any manner.

The figures and descriptions provided herein may have been simplified to illustrate aspects that are relevant for a clear understanding of the herein described devices, systems, and methods, while eliminating, for the purpose of clarity, other aspects that may be found in typical devices, systems, and methods. Those of ordinary skill may recognize that other elements and/or operations may be desirable and/or necessary to implement the devices, systems, and methods described herein. Because such elements and operations are well known in the art, and because they do not facilitate a better understanding of the present disclosure, a discussion of such elements and operations may not be provided herein. However, the present disclosure is deemed to inherently include all such elements, variations, and modifications to the described aspects that would be known to those of ordinary skill in the art.

A perspective view of an air handling unit, with duct hosesandattached thereto, and connected to drop ceiling, is shown in. Portable air handling unitmay be a conventional portable air-conditioner or heater. Portable air handling unit, illustratively, includes dual outlets that each receive a duct hose, such as duct hosesand, as shown, to exhaust warm air generated by portable air handling unit. That warm air can be exhausted to a space separate from interior space. It is appreciated that such portable air handling units may include one exhaust port requiring one duct hose or multiple exhaust ports requiring multiple duct hoses.

Such portable air handling unitsmay be placed in interior spacein circumstances when built-in central air-conditioners, for example, fail and cool air is needed before repairs can be made. However, warm air that is generated by portable air handling unitmust be exhausted somewhere other than interior space. One or more duct hoses, such as duct hosesand, illustratively shown here, receive the warm air from portable air handling unitto direct out of interior space. In this case, interior spaceincludes a drop ceiling, as shown.

Drop ceilings are well-known structures composed of a grid of longitudinally extending metal channels suspended from the ceiling. Such metal channels, such as channelsshown herein, are suspended over interior space. The grid formed by channelscreate open spaces that are filled by ceiling tiles or panels, which make up the drop ceiling surface. Duct hosesandextend through prior art ceiling panelsand, respectively, to exhaust the warm air above drop ceiling. Because of this space between the actual structural ceiling above interior spaceand drop ceiling, the warm air can fill that space and keep segregated from interior spacebelow. It is appreciated that ceiling panelsandmay include openings that correspond to the size of duct hosesand, to provide a fluid passageway from air handling unit, up to the space above drop ceiling.

A collar or ring-shaped flange may be located about the periphery of the opening in ceiling panelsandand extend downward to provide a structure for duct hosesand/orto attach to. Because panels, such as ceiling panels, are typically removable from channels, air handling unitcan be placed at any desired location, and then one or more of ceiling panelsremoved and replaced with either one or more prior art ceiling panelsand/orhaving the ringed openings disposed therein. Either or both duct hosesand/or, respectively, may be connected to the ceiling panels as needed to exhaust the warm air. These ceiling panelsandare only temporarily placed on channelsof drop ceiling, however. Once the central HVAC system is repaired, portable air handling unitis no longer needed. Duct hosesandare disconnected from ceiling panelsandand removed. Ceiling panelsandare then removed as well, and the openings in drop ceilingreplaced with conventional ceiling panels. This system makes a convenient way of temporarily installing an air handling unit for providing the necessary cool air in interior space, as needed, and then removed with no signs of having been there. Because drop ceilingis composed of several removable ceiling panels, it is a sufficient solution for exhausting the warm air from almost anywhere within interior space. Any of ceiling panelscan be removed anywhere within interior spaceto place portable air handling unit, as needed.

A potential issue that can occur with these duct hosesand/or, is that they can become loose or fall when temporarily coupled to the flanges on ceiling panelsand/or, respectively. Gravity and vibration at the junction between the flanges and the duct hoses might negatively affect the coupling between the two structures.

Accordingly, an illustrative embodiment of the present disclosure provides a ceiling duct insert that includes an attachment flange for the duct hose located about the periphery of an opening to allow air to flow above the insert. The flange in this case has a flared outer surface from top to bottom to better assist mounting and holding the duct hose onto the ceiling duct insert. The flared or negative angled flange has a narrower diameter at the opening in the panel and a wider diameter at the distal or bottom end portion of the flange. This negative angled arrangement on the flange provides a support that a flange having a perpendicularly-oriented surface does not provide. In other embodiments, the flared surface of the flange can be at other locations on its surface.

A perspective view of a ceiling duct insertis shown in. This view depicts panel bodythat approximates the size, shape, and characteristics of a conventional drop ceiling panel like ceiling panel. Ceiling duct insert, however, includes an openingdisposed therethrough for purposes of allowing air to pass from the duct hose (connected to portable air handling unit) through ceiling duct insert, and into the space above drop ceiling. Surrounding openingis a flared ring or flange. A duct hose, such as duct hoseor, can be configured with a corresponding diameter to fit over flared flangeand connect the two for purposes of creating a fluid passageway for the warm air moving from portable air handling unitup to the space above ceiling duct insert. Because flared flangehas a negative angle associated with it (see, also,), a twist tie, zip tie, buckle, strap or other like attachment means can wrap around flared flangeto better hold the duct hose in place despite its weight and any vibration generated on the duct hose.

A side view of ceiling duct insertis shown in. This view depicts panel bodylaterally extending similar to that of a conventional drop ceiling panel, such as ceiling panelshown in. It is appreciated that the physical characteristics, including dimensions of panel body, are similar to that of ceiling panelso that panel bodycan be placed onto channelsof drop ceilingthe same as ceiling panel. Extending from ceiling duct insertis flared flangethat surrounds opening(see). Flared flangeincludes a first outer diameter, proximate to panel body, of about 5.8 inches to about 23.8 inches. Distal from panel bodyis the outer diameter of flared flangehaving an outer surface diameterof about 5.9 inches to about 23.9 inches. It is appreciated that outer surface diameterwill be narrower than outer surface diameter. This is what creates the flare or negative angle for flared flange. By flaring outer surface diameteroutward further than outer surface diameter, either of duct hosesorcan better couple onto outer surfaceof flared flange. Duct hosesorcan be coupled to flared flangevia zip tie, buckles, straps or other like means. Outer surface diameter, being narrower than outer surface diameter, means that the zip tie, straps, etc. fit tighter about outer surfacenear base panel body. Duct hosesordo not slide off because the zip ties or straps form a narrower loop than outer surface diameter. This causes a wedging effect due to the attaching mechanism getting tighter against the larger diameter. In some illustrative embodiments, a ridgemay extend outwardly of openingon outer surface, for purposes of further assisting duct hosesorto selectively attach to flared flange.

A detail side view of a portion of ceiling duct insertis shown in. In particular, this view depicts a portion of flared flangedemonstrating the anglebetween outer surface diameterand outer surface diameter. As illustratively shown, outer surfaceof flared flangeangles outward as it extends from panel body. Rather than flared flangeextending orthogonal (i.e., the angle between linesand) to panel body, it extends at about an about 87.23 degree angle. Thus, outer surfacemay extend at an about 87.2 degree angle as identified by anglelocated between linesand. It is appreciated that angle, located between linesand, may alternatively be about 89.99 degrees to about 46 degrees. Again, this allows duct hosesorto be releasably coupled to flared flange. In other embodiments, the angles may be steeper or shallower.

Another illustrative embodiment of the present disclosure provides opposing duct flanges on each side of the ceiling duct insert. This allows a duct hose to couple to each side of the ceiling duct insert (see, e.g.,) to allow warm air to pass through the drop ceiling and continue through another duct hose that leads to another location. For example, duct hoses can be placed in the space above a drop ceiling to direct air to larger spaces such as common or less impacted areas. Duct hoses above the drop ceiling can also direct air outside of the building.

A perspective view of ceiling duct insertis shown in. Like ceiling duct insertfrom, ceiling duct insertapproximates the size, shape, and characteristics of a conventional drop ceiling panel like panel. In contrast to ceiling duct insert, however, ceiling duct insertincludes flared ring or flangethat encircles the periphery of openingon the opposite side of panel body. By this configuration, ceiling duct insertincludes additional utility by providing a flangeto removably couple or attach to another duct hose above ceiling duct insert.

A top perspective view of ceiling duct insertis shown in. This perspective view is reverse of the perspective view of ceiling duct insertshown in. Here, panel bodyis further shown to be that similar to ceiling panelwith the exception of openingdisposed therethrough. This view also shows flangeextending upwardly from openingwhile flared flangeextends downward on the opposite side of ceiling duct insert. In this way, a first duct hose, like either of duct hosesor, may be removably coupled to flared flangewhile a separate duct hose above drop ceilingmay be removably coupled to flange.

A side elevational view of ceiling duct insertis shown in. This view is similar to the view of ceiling duct insertshown in, except, again, with flangeextending in the opposite direction above panel bodyand away from flared flange. Like that discussed with respect to flared flange, flangehas an outer surface diameter, proximate to panel body, surrounding opening, that is narrower than outer surface diameterof flange, which is distal from panel body. Outer surface diametermay be about 5.8 inches to about 23.8 inches, while outer surface diametermay be about 5.9 inches to about 23.9 inches. This creates the flare or negative angle for flange. By flaring outer surface diameterfurther than outer surface diameter, duct hoses can strap onto the narrower portion of outer surfaceof flange. In some illustrative embodiments, a ridgemay extend outwardly of openingon outer surfacefor purposes of further assisting a duct hose to selectively attach to flange.

A detail side view of a portion of ceiling duct insertis shown in. In particular, this view depicts a portion of flangedemonstrating the anglebetween outer diameterand outer diameter. Rather than flangeextending orthogonal (i.e., the angle between linesand) to panel body, angleextends at about 87.23 degree angle, like flared flange. Thus, outer surfacemay extend at an about 87.2 degree angle as identified by anglelocated between linesand. It is appreciated that the angle, located between linesand, may alternatively be about 89.99 degrees to about 45 degrees. In other embodiments, the angles may be steeper or shallower. In further embodiments, outer surfaceof flangemay be oriented orthogonal to panel bodydifferent than flared flangeextending downward.

A side elevation view of ceiling duct insertis shown in. This view is similar to that ofexcept in this case a first duct hoseis removably coupled to flared flangewhile a second duct hoseis removably coupled to flangeopposite flared flange. It is appreciated that duct hoseis in fluid communication with openingso that air directed up through duct hosepasses through panel bodyof ceiling duct insert, and directed to a remote location. A zip tie, strap, buckle, or other like securing means can be wrapped around endof duct hoseto secure same onto flared flange. Similarly, such securing means can be wrapped around endof duct hoseto secure same to flange.

In the drawings, some structural or method features may be shown in specific arrangements and/or orderings. However, it should be appreciated that such specific arrangements and/or orderings may not be required. Rather, in some embodiments, such features may be arranged in a different manner and/or order than shown in the illustrative figures. Additionally, the inclusion of a structural or method feature in a particular figure is not meant to imply that such feature is required in all embodiments and, in some embodiments, may not be included or may be combined with other features. It should also be appreciated that any subject matter disclosed in this non-provisional patent application that may differ from the priority application, the disclosure from this non-provisional patent application controls.