Spray coated insulated plenum box and method

Abstract

An insulated plenum box, such as a ceiling box or any other metal plenum box, for heating, ventilating and air conditioning (HVAC) duct systems is produced faster and cheaper than prior art devices by having insulation sprayed onto either the inside or the outside of the plenum box to match the R-value of the connecting insulated HVAC duct, saving time, labor, and cost for the end user by eliminating the step of insulating the plenum box at installation.

1 . A pre-sprayed coated insulated plenum box device, such as a ceiling box or any other metal plenum box for a heating, ventilating or air conditioning (HVAC) duct system, the device comprising:
 a metal plenum box comprising a rigid structure having a vent opening and a duct connecting opening for interconnecting with at least one insulated HVAC duct, an interior surface housing a passageway interconnecting the vent opening and the duct connecting opening, an exterior surface attachable at one end to an opening in a building structure and attachable at an opposite end to the at least one HVAC duct, and at least one layer of pre-sprayed insulation coating of a desired resistance value (R-value) to match the duct covering at least one of the surfaces to insulate the plenum box and restrict temperature losses from the plenum box so that the pre-spray coated insulated plenum box device may be directly installed by an installer in a ceiling and connected to insulated HVAC ducts for a completely insulated duct system with a matching R-value throughout.   
     
     
         2 . The device of  claim 1  wherein the at least one layer of sprayed insulation coating covers the interior surface. 
     
     
         3 . The device of  claim 1  wherein the at least one layer of sprayed insulation coating covers the exterior surface. 
     
     
         4 . A method of pre-spray coating insulation on a plenum box, such as a ceiling box or any other metal plenum box, for a heating, ventilating or air conditioning (HVAC) duct system, the method comprising:
 a step of pre-spray coating insulation on a metal plenum box comprising a rigid structure having a vent opening and a duct connecting opening for interconnecting with at least one insulated HVAC duct, an interior surface housing a passageway interconnecting the vent opening and the duct connecting opening, an exterior surface attachable at one end to an opening in a building structure and attachable at an opposite end to the at least one insulated HVAC duct, the step comprising pre-spraying at least one layer of insulation coating to cover at least one of the surfaces to insulate the plenum box to match the resistance value (R-value) of the at least one insulated HVAC duct and restrict temperature losses from the plenum box to form a pre-spray coated insulated plenum box device so that a user may directly install the pre-spray coated insulated plenum box in a building structure and connect the pre-spray coated insulated plenum box to insulated HVAC ducts for a completely insulated duct system having a uniform R-value throughout.   
     
     
         5 . The method of  claim 4  comprising pre-spray coating insulation on the interior surface of the metal plenum box. 
     
     
         6 . The method of  claim 4  comprising pre-spray coating insulation on the exterior surface of the metal plenum box.