Mud-In Air Register with Magnetically Adjustable Damper

This application claims priority to U.S. Application No. 63/660,315, filed Jun. 14, 2024, which application is incorporated herein by reference in its entirety.

The present disclosure relates generally to air registers having a magnetically adjustable damper.

Air registers are an essential component of heating, ventilation, and air conditioning (HVAC) systems in buildings and are installed at the end of air ducts to control/direct the flow of conditioned air into rooms. Traditional air registers typically consist of a grille or faceplate with adjustable louvers or vanes that allow users to manually control the direction and volume of airflow. The primary function of these registers is to ensure that the conditioned air is distributed evenly throughout the space, contributing to the overall comfort and efficiency of the HVAC system. However, traditional air registers are not aesthetically pleasing, and designing a room in a way that limits the visibility of air registers while not significantly decreasing the efficiency of HVAC systems has been an issue since HVACs were invented in the 1930s. In recent years, there has been an increased demand for more efficient and aesthetically pleasing HVAC solutions, particularly in residential and commercial construction. This has led to the development of various types of air registers, including mud-in registers that can be installed flush with walls or ceilings for a seamless appearance. This trend towards more sophisticated air register designs reflects a broader shift in the construction industry towards integrating functional elements seamlessly into architectural aesthetics. Mud-in registers, in particular, have gained popularity due to their ability to blend into surrounding surfaces, creating a clean and unobtrusive look that appeals to modern design sensibilities.

However, while mud-in registers offer aesthetic advantages, they have historically faced challenges in terms of performance and adjustability. Many early designs sacrificed functionality for appearance, lacking features such as effective air damping or directional control. This limitation has created a need for innovative solutions that can combine the visual appeal of mud-in registers with the practical benefits of traditional air registers, such as adjustable airflow and directional control.

Additionally, in the broader context of housing construction, there is an increasing demand for faster construction methods at lower costs. Builders and developers are seeking innovative solutions that can streamline the construction process, reduce labor costs, and enhance the overall energy performance of buildings. This shift towards more efficient construction methods and materials has implications for all aspects of building design, including HVAC systems and their components such as air registers. The need for cost-effective and time-efficient construction solutions has driven the development of new materials and technologies that can be easily integrated into modern building practices.

Accordingly, there is a need in the art for air registers having magnetically adjustable dampers that will allow for control of a flow of air from an HVAC system when an air register is seamlessly integrated into a wall.

An apparatus, system, and method for controlling airflow in an HVAC system is provided. In one aspect, the apparatus, system, and method allow for users to adjust an amount of air flow and/or direction of air flow without the need for direct contact with the air register or electronics. In another aspect, the apparatus, system, and method allow users to control a damper having no visible mechanism to manipulate. In yet another aspect, the apparatus, system, and method allow a user to adjust an amount of air flow and/or direction of air flow of an air register that has been seamlessly integrated into wall. Generally, the apparatus, system, and method allow users to control various aspects of airflow through an air register. The apparatus, system, and method comprises a magnetically adjustable damper system having a damper configured to slidably attach to an air register.

The damper is configured to slide between an open position and a closed position on the air register. A sealing member of the damper is configured to interface with the air register in a way such that airflow is restricted by the sealing member when the damper is placed in the closed position. The damper comprises at least one magnetic positioning element. A magnetic force applied via the at least one magnetic positioning element causes the damper to slide between the open position and the closed position. A magnetic field may be created between the magnetic positioning element and a magnetic fob, allowing the damper to be moved between open and closed positions without direct physical contact. This magnetic actuation provides a smooth and efficient method of controlling the damper's position without any externally visible controls.

The air register is designed to be secured to a register boot of ductwork and features a plurality of slats that create openings for airflow. These slats are specifically arranged to direct air from the ductwork into the building space at any angle from 5 degrees to 85 degrees, providing a wide range of options to suit different room layouts and ventilation needs. This flexibility ensures that the air can be distributed evenly throughout the space, enhancing the overall comfort and efficiency of the HVAC system. The slats are preferably set at a 45-degree angle, which has been found to provide optimal air distribution for most standard room configurations. This angle allows for a balanced mix of horizontal and vertical airflow, ensuring that the conditioned air reaches all areas of the room effectively.

The apparatus may include first bearing magnetic elements attached to the damper and second bearing magnetic elements attached to the air register. These bearing magnetic elements generate an attractive magnetic force between them, which helps to maintain the damper's position and ensure smooth operation. A set of rollers may be included to facilitate smooth movement of the damper between the open and closed positions. These rollers may be housed in a roller channel that moveably secures them between the air register and the magnetically adjustable damper system. A first magnetic catch may be secured to the air register and a second magnetic catch secured to the magnetic damper. These catches are configured to hold the damper in either the open or closed position, providing stability and preventing unwanted movement. According to another aspect of the present disclosure, the apparatus may include a plurality of sealing members on the damper, configured to interface with the plurality of slats on the air register. This configuration ensures that when the damper is in the closed position, all openings created by the slats are effectively sealed, providing complete airflow control.

The foregoing summary has outlined some features of the apparatus, system, and method of the present disclosure so that those skilled in the pertinent art may better understand the detailed description that follows. Additional features that form the subject of the claims will be described hereinafter. Those skilled in the pertinent art should appreciate that they can readily utilize these features for designing or modifying other structures for carrying out the same purpose of the apparatus, system, and method disclosed herein. Those skilled in the pertinent art should also realize that such equivalent designs or modifications do not depart from the scope of the apparatus, system, and method of the present disclosure.

In the Summary above and in this Detailed Description, and the claims below, and in the accompanying drawings, reference is made to particular features, including method steps, of the invention. It is to be understood that the disclosure of the invention in this specification includes all possible combinations of such particular features. For example, where a particular feature is disclosed in the context of a particular aspect or embodiment of the invention, or a particular claim, that feature can also be used, to the extent possible, in combination with/or in the context of other particular aspects of the embodiments of the invention, and in the invention generally. The term “comprises” and grammatical equivalents thereof are used herein to mean that other components, ingredients, steps, etc. are optionally present. For example, an article “comprising” components A, B, and C can contain only components A, B, and C, or can contain not only components A, B, and C, but also one or more other components. As used herein, the term “magnetic” and grammatical equivalents thereof means a material that is capable of being magnetized or attracted by a magnet. For example, both a neodymium magnet and a piece of steel would both be considered magnetic.

illustrate a systemin the form of an air register assembly designed to control airflow in an HVAC system.depicts a front, perspective view of an air register having a magnetic dampening system.depicts a rear, plan view and an air register having a magnetic dampening system, wherein the magnetic dampening system is configured to slide between an open position and closed position.depicts an exploded view of an air register having a magnetic dampening system, wherein wheels assist the magnetic dampening system smoothly transition between the open position and closed position.depicts a side-view of an air register having a magnetic dampening system secured to a register boot.depicts a front, perspective view of an air register having a magnetic dampening system that has been secured to a register boot.depicts a cross-sectional view showing air flowing through an air register having a magnetic dampening system and the register boot secured to the air register. It is understood that the various method steps associated with the methods of the present disclosure may be carried out by a user using the air register having a magnetic dampening system depicted in.

As illustrated in, the systemgenerally comprises an air register, magnetically adjustable damper system, and register bootof an HVAC system. In embodiments of the systemwhere said air registeris a mud-in air register, the air registerin combination with the magnetically adjustable damper systemallow for precise control of a flow of air from an HVAC system into a building expanse without compromising the aesthetic design of the space. The magnetically adjustable damper systemis preferably configured to slidably secure to the air register and slide between an open position and a closed position, wherein a magnetic force is used to move said magnetically adjustable damper systembetween said open position and a closed position. In some preferred embodiments, the magnetically adjustable damper systemincludes at least one sealing member that interfaces with the air register in a way such that airflow is restricted when the magnetically adjustable damper systemis in the closed position.

As illustrated in, the systemcomprises an air registerthat forms the outer structure of the device. The air registeris preferably designed to secure to a boot flangeof a register boot, wherein said register bootis a part of the ductwork of an HVAC system. In some preferred embodiments, a plurality of slats and/or a plurality of airflow vanesare arranged in parallel across the width of the assembly, creating a plurality of openings that allow for a flow of air to move from the ductwork into a building expanse through said system. The plurality of airflow vanesare preferably designed in a way such that they direct the flow of air passing through the register. In one preferred embodiment, the plurality of airflow vanesmay be configured to direct the flow into one or more directions and/or one or more angles. The plurality of airflow vanesare preferably configured to angle a flow of air between 5 to 85 degrees. In one preferred embodiment, the plurality of airflow vanesare all angled at 45 degrees.

The air registermay be constructed from metals such as aluminum or steel, which can be die-cast or stamped to create the desired shape and features. Alternatively, the air registermay be injection molded using high-performance thermoplastics like ABS (Acrylonitrile Butadiene Styrene) or polycarbonate. In some preferred embodiments, a combination of materials may be used, with metal components for structural integrity and plastic components for weight reduction and cost-effectiveness. In other preferred embodiments, the airflow vanesmay be manufactured separately and assembled into the main body. However, in a preferred embodiment, the airflow vanesare integrally formed during the molding or casting process used to create the air register, depending on the specific design requirements and manufacturing capabilities.

Materials that may be used to construct the air register include, but are not limited to, metals, plastics, wood, composites, or any combination thereof. Air registers constructed from metals may be used in applications where strength and durability are needed. Types of metals that may be used to construct the air register include, but are not limited to, aluminum, steel, stainless steel, brass, copper, bronze, galvanized steel, or any combination thereof, which may be chosen based on a desired attribute of the metal. For instance, aluminum may be favored in instances where weight and corrosion resistance are primary concerns, such installation in coastal areas or industrial settings. For instance, steel may be preferred in applications where its superior strength and rigidity make it capable of withstanding impacts, heavy loads, and other physical stresses without deforming or breaking, such as installation in high-traffic areas, commercial buildings, and industrial facilities where durability and resilience are critical. Additionally, air registers made from metals can be treated with various coatings or finishes to enhance its corrosion resistance, further extending its lifespan and versatility. Air registers made from metals are preferably die-cast, stamped, or printed to create the desired shape and features of the air register.

Air registersconstructed from plastics may be used in applications where weight, impact resistance, corrosion resistance, and costs are a concern. Types of plastics that may be used to construct the air register include, but are not limited to, ABS (Acrylonitrile Butadiene Styrene), polycarbonate, polypropylene, polyethylene, PVC (Polyvinyl Chloride), polyamide, Acetal (Polyoxymethylene), Polyurethane, and High-Impact Polystyrene (HIPS, which may be chosen based on a desired attribute of the plastic. For instance, ABS may be favored in instances where toughness, impact resistance, and ease of processing are primary concerns. For instance, Polycarbonate may be favored in instances where high impact resistance and thermal stability are primary concerns. Air registers made from plastics are preferably injection molded or printed to create the desired shape and features of the air register.

In some preferred embodiments, a combination of materials may be used to make the air register. For instance, metal components may be incorporated for structural integrity and durability, while plastic components may be used for weight reduction and cost-effectiveness. This hybrid approach allows for the optimization of the air register's performance and manufacturing efficiency. For instance, the airflow vanes, which are critical for directing the flow of air through the register, may be manufactured separately and assembled into the main body of the air registerat later point of the manufacturing process Accordingly, some embodiments of the air registermay be produced using different materials or methods to achieve the desired performance characteristics. In one preferred embodiment, the plurality of airflow vanesmay be made from lightweight plastics using an injection molding process whereas the main body of the air register may be made from steel and manufactured using a die casting process.

The outer periphery of the air registermay comprise a recessed flangedesigned to create a seamless integration between the air register and the surrounding wall or ceiling surface. By incorporating a recessed flange, the air register can be installed in a way that minimizes its visual impact, contributing to a clean and unobtrusive appearance that aligns with modern design sensibilities. In some preferred embodiments, a cavity of the recessed flangemay be filled with drywall compound to create a smooth transition between the drywall, or other wall surface, and the air register assembly. During installation, the air register may be positioned so that the recessed flange sits slightly below the surface of the drywall. Once the air register is secured in place via securement to the register boot, the cavity created by the recessed flange may be filled with drywall compound, also known as joint compound or mud.

Some preferred embodiments of the air registermay further comprise one or more screw holesthat are positioned about the recessed flange. The screw holesmay serve as a mounting point for attaching the air register assembly to a register bootor other structure. In some preferred embodiments, the air registermay attach to the register bootusing adhesives, magnetism, press fit, or any combination thereof. As illustrated in, the air registerpreferably comprises a rear faceconfigured to interface with the register boot. In a preferred embodiment, the air registermay comprise a boot seal cavitylocated on the rear face, wherein said boot seal cavityat least partially encircles the plurality of slats and/or the plurality of airflow vanes. The boot seal cavityis preferably configured to receive a boot flangeof a register boot, securing the air register to the register boot. In some preferred embodiments, a sealing mechanism may be used with the boot seal cavity, such as a foam or rubber gasket, configured to create an air tight connection between the register bootand the air register. Accordingly, the sealing mechanism may help to prevent air leakage and improve the efficiency of the HVAC system. In some preferred embodiments, the air register may further comprise retaining clips, which may be used to ensure that the damperremains in place while sliding between the open position and closed position. Retaining clipsmay be attached to the air registeror may be formed integrally with the air register.

In a preferred embodiment, as illustrated in, a first magnetic catchof the system is configured to magnetically attach to a second magnetic catch of the system. The first magnetic catchis preferably secured to the air register. In one preferred embodiment, the first magnetic catchand second magnetic catchcomprise a magnet. In another preferred embodiment, one of the first magnetic catchand second magnetic catchcomprise a magnet and one of the first magnetic catchand second magnetic catchcomprise an angular metallic section designed to magnetically attach to the magnet (See). The first magnetic catchand the second magnetic catchpreferably work together to hold the damperin either the open or closed position, providing a stable and reliable means of controlling airflow. In other embodiments, additional magnetic catches may be used to hold the damperin the complimentary position. Alternatively, the first magnetic catchor the second magnetic catchmay be configured to hold the damperin both the open and closed position.

As illustrated in, the systempreferably comprises a magnetically adjustable damper systemhaving a first bearing magnetic element, first magnetic catch, second bearing magnetic elements, second magnetic catch, damper, rollers, retaining clips, and magnetic positioning element. In a preferred embodiment, the magnetically adjustable damper systemis configured to moveably secure to the air registerin a way such that manipulation of the magnetically adjustable damper systemallows a user to control the flow of air therethrough. The damperpreferably of the magnetically adjustable damper systempreferably comprises a rectangular body having a series of openings spaced complimentary to that of the plurality of slats and/or plurality of airflow vanesof the air register. Thus, when the damperis in a first position (open), openings in the damperare aligned with the openings in air registerand air may flow through the air register assembly. When the damperis in a second position (closed), openings in the damperare not aligned with the openings in the air register(i.e. the solid portions of damper, also referred to as a sealing member, cover the openings in the air register) and airflow is restricted through the system.

In a preferred embodiment, as illustrated in, a first magnetic catchof the system is configured to magnetically attach to a second magnetic catchof the system. The first magnetic catchis preferably secured to the air registerwhereas the second magnetic catchis secured to the damper. In one preferred embodiment, the first magnetic catchand second magnetic catchcomprise a magnet. In another preferred embodiment, one of the first magnetic catchor second magnetic catchcomprise a magnet and one of the first magnetic catchor second magnetic catchcomprise a ferromagnetic section designed to magnetically attach to the magnet (See). The first magnetic catchand the second magnetic catchpreferably work together to hold the damperin either the open or closed position, providing a stable and reliable means of controlling airflow once the damperis put in the desired position relative to the air registerby a user. In other embodiments, additional magnetic catches may be used to hold the damperin the complimentary position. Alternatively, the first magnetic catchor the second magnetic catchmay be configured to hold the damperin both the open and closed position. The first magnetic catchor the second magnetic catchare preferably secured to the air registerand the damperusing various attachment methods, including, but not limited to, press fits, adhesives, screws, rivets, or other fastening methods. In other preferred embodiments, the first magnetic catchor the second magnetic catchmay be integrally formed with the air registerand the damperduring the manufacturing process.

To facilitate adjustment of the damper(i.e. opening or closing), magnetic positioning elementsare retained within positioning magnet pocketsof positioning magnet protrusionsof the damper. This arrangement allows the magnetic positioning elementsto be close to the front faceof air registerto facilitate magnetic adjustment. In a preferred embodiment, a magnetic force applied to the magnetic positioning elementcauses the damperto slide between the open and closed positions. In a preferred embodiment, this magnetic force may be applied by the use of a magnetic fob controlled by a user, allowing the damperto be adjusted magnetically and without any externally visible controls.

A magnetic fob used for adjusting the dampermay comprise one or more magnetic elements configured to generate an attractive force with the magnetic positioning elementthat is great enough to allow a user to slide the magnetically adjustable damper systembetween the open position and closed position. In some preferred embodiments, at least one the magnetic element of the fob or the magnetic positioning elementof the magnetically adjustable damper systemcomprises a magnet. Types of materials that may be used to create the magnets of the system include, but are not limited to, neodymium, ferrite, and alnico. In other embodiments, the magnetic element of the fob or the magnetic positioning elementof the magnetically adjustable damper systemmay be made of a ferromagnetic material. Types of materials that may be used as a ferromagnetic material of the system include, but are not limited to, iron, nickel, and cobalt. The specific material used to create the magnet or components made of a ferromagnetic material may be selected based on factors such as the desired strength of the magnetic force, the desired weight of the various components, and the environmental conditions that the systemmay be exposed to. In a preferred embodiment, the magnetic fob may be designed to be handheld, providing a convenient and portable means of adjusting the damper. The magnetic fob may include a handle or grip portion for easy handling, and the magnets of the magnetic fob may be located at the opposite end of said handle. The magnetic fob may be made of a variety of materials, including but not limited to plastic, metal, or a combination thereof.

The first bearing magnetic elementis configured to interact with second bearing magnetic elements(See) attached to the damperto generate an attractive magnetic force that aids in the movement of the damper. In a preferred embodiment, the first bearing magnetic elementsmay be first placed into the roller channelsand then therollers placed therein. When the damperis installed onto the air register, the rollersare sandwiched between the damperand the first bearing magnetic elements. An attractive magnetic force between the first bearing magnetic elementand second bearing magnetic element, holds the damperin place, producing smooth sliding action, and reducing vibration or chatter of the damper. In some cases, the first and second bearing magnetic elements,may be secured to the damperand the air register, respectively, using various attachment methods. For example, the first and second bearing magnetic elements,may be attached using press fits, adhesives, screws, rivets, or other fastening methods. In other cases, the first and second bearing magnetic elements,may be integrally formed with the damperand the air register, respectively, during the manufacturing process. For example, the first and second magnetic elements may be placed into an injection mold and the air registeror dampermolded over the magnetic elements.

In some embodiments, as illustrated in, roller channelsplaced near the corners of the air registermay be used in combination with a rollerof the magnetically adjustable damper system. Each roller channelis preferably designed to contain a first bearing magnetic elementand a rollerof the magnetically adjustable damper system, wherein the rolleris configured to facilitate smooth movement of the damperbetween the open position and closed positions. The rollerspreferably comprise a low-friction material such as nylon, polytetrafluoroethylene (PTFE), or a similar material. In some cases, the rollersmay be ball bearings or roller bearings. The specific design and material of the rollersmay be selected based on factors such as the weight of the damper, the desired smoothness of movement, and the environmental conditions within the HVAC system.

illustrate the air register assembly secured to a register bootas well as how the air register assembly functions with the register boot. As illustrated in, air register is configured to interface with the register bootand preferably comprises a boot inlet, installation flange, boot body, and register flange. The boot bodyforms the primary structure of the register boot, providing a framework for the other components. The boot inletis attached to the boot bodyand is designed to attach to ducting of the HVAC system to supply air to the register boot. The register flangeof the register bootextends from the boot bodyand at least partially encircles the air exit hole of the boot body. In a preferred embodiment, the register flangeis designed to extend into the boot seal cavityof the air registerupon installation of the air register, resulting in secure placement of the air register assembly as well as a tighter seal between the register bootand the air register. In some preferred embodiments, a sealing member of the register flange, such as a foam or rubber seal, may be used to further enhance the seal.

Securement of the air registerto the register bootmay be achieved using various attachment methods, including, but not limited to, screws, rivets, adhesives, or press fits. In one preferred embodiment, the air registermay be magnetically secured to the register boot. For example, the air registermay include one or more magnetic elements that interact with corresponding magnetic elements on the register bootto hold the air registerin place. These magnetic elements used for securing the air register assembly to the register bootmay be a separate magnetic element. In another preferred embodiment, the various magnets of the magnetically adjustable damper system—including the first bearing magnetic element, the second bearing magnetic element, the positioning magnets, the first magnetic catch, or the second magnetic catch, or any combination thereof—may be used to secure the air registerto the register bootvia interaction with corresponding magnetic elements on the register boot.

As illustrated in, the air registerforms the outer facing portion of the system. of the plurality of slats and/or plurality of airflow vanesare preferably arranged vertically in parallel and are designed to direct the flow of air passing through the system as it moves into a building expanse. The screw holespositioned at the top and bottom center of the air registermay be used for mounting the air register assembly to the register boot.

As illustrated in, the installation flangeis visible around the perimeter of the air registerand provides a surface for orienting the boot bodyto the surrounding wall or ceiling structure during installation of the register boot. Unlike existing air register designs, the systemdescribed herein can be installed prior to the installation of drywall, eliminating the need for the HVAC contractor to return to the jobsite after drywall installation. Once the drywall is installed around the air register assembly, the drywall installer can use drywall compound to fill the gap between the drywall and the front faceof the air register assembly to create a streamlined appearance that would integrate into various interior settings, with the airflow vanesbeing the primary visible functional elements of the finished construction. This installation method may provide advantages in terms of construction efficiency and aesthetic design.

The systemis designed to direct airflow at a 45-degree angle. This is in contrast to the straight airflow entering the register boot, as indicated by the straight arrows in.

In some preferred embodiments, the angle of the flow of air may be adjusted by adjusting the position of the damper. For example, when the damperis in an open position, the airflow may be directed at a 45-degree angle. When the damperis in a closed position, the airflow may be restricted or directed at a different angle. This adjustable airflow direction may provide additional flexibility in controlling the HVAC system and tailoring the airflow to the specific needs of the room. In other embodiments, the air register assembly may be designed to direct airflow at different angles, depending on the specific design of the airflow vanesand the position of the damper. This wide range of airflow angles may provide additional flexibility in controlling the HVAC system and tailoring the airflow to the specific needs of the room.

The implementations set forth in the foregoing description do not represent all implementations consistent with the subject matter described herein but are examples consistent with the disclosed subject matter. Although variations have been described in detail above, other modifications or additions may be possible. In particular, further features and/or variations may be provided in addition to those set forth herein. For example, the implementations described above may be directed to various combinations and subcombinations of the disclosed features and/or combinations and subcombinations of several further features disclosed above. In addition, the logic flow depicted in the accompanying figures and/or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. It will be readily understood to those skilled in the art that various other changes in the details, materials, and arrangements of the parts and method stages which have been described and illustrated in order to explain the nature of this inventive subject matter may be made without departing from the principles and scope of the present disclosure.