AIRFLOW SYSTEM

Abstract

An airflow system is provided that includes an interior strip that attaches an interior surface of a wall support assembly, a rear sheet attached to a rear exterior of the wall support assembly, a front sheet attached to a front exterior of the wall support assembly. The interior strip, rear sheet, and front sheet form a flame retardant interior channel that facilitates the transfer of airflow to and from an airflow source.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent application Ser. No. 62/014,480 entitled "AIRFLOW SYSTEM" filed on Jun. 19, 2014. The entirety of the above-noted application is incorporated by reference herein.

ORIGIN

[0002] The innovation disclosed herein relates to improving airflow and more specifically to improving the airflow in a heating and cooling system.

BACKGROUND

[0003] Currently, in a heating, ventilation, and air conditioning (HVAC) system metal ductwork is used to transfer airflow from a source (e.g., furnace, air conditioner, etc.) to a destination (e.g., dwelling, building, etc.). Metal ductwork, however, has a tendency to leak as the air travels from the source to the destination. For example, air leakage occurs at a seam of the ductwork, at a joint where two pieces are connected, at bend points in the ductwork, etc.

[0004] In addition, metal ductwork is costly to manufacture, store, transport, and install. Still further, installers must wear heavy gloves, which make it difficult to handle the ductwork, in order to prevent cuts that occur when handling the metal ductwork. Another disadvantage to the conventional metal ductwork is that when the system is operational and air is flowing, the metal ductwork shifts and pops thereby creating noise that can be heard throughout the facility.

SUMMARY

[0005] The following presents a simplified summary in order to provide a basic understanding of some aspects of the innovation. This summary is not an extensive overview of the innovation. It is not intended to identify key/critical elements or to delineate the scope of the innovation. Its sole purpose is to present some concepts of the innovation in a simplified form as a prelude to the more detailed description that is presented later.

[0006] In an aspect of the innovation an airflow system is provided that includes an insert configured to attach to wall support members to transfer an airflow from an entry point to an exit point and a cover configured to attach to the insert and wall support members thereby providing a seal over the insert, wherein the attachment of the cover forms a channel to facilitate the transfer of the airflow.

[0007] In another aspect of the innovation an airflow system is disclosed that includes a first portion having a first surface made from a flame retardant material and a second surface and being attached to an interior surface of a wall support assembly so that the second surface is facing the interior surface thereby covering the interior surface; a second portion having a first surface made from a flame retardant material and being attached to a rear exterior portion of the wall support assembly so that the first surface is facing the rear exterior portion thereby covering the rear exterior surface; and a third portion having a first surface made from a flame retardant material and being attached to a front exterior surface of the wall support assembly so that the first surface is facing the front exterior portion thereby covering the front exterior surface, wherein attachment of the first portion, second portion, and third portion enclose the wall support assembly and form a channel within the wall support assembly that facilitates a transfer of airflow.

[0008] In still yet another aspect of the innovation a method installing an airflow system is disclosed that includes providing a material having at least one flame retardant surface; attaching a first portion of the material to an interior surface of a wall support assembly; attaching inner flaps, formed by the attachment of the first portion, to exterior surfaces of the wall support assembly; attaching a second portion to a rear exterior surface of the wall support assembly; attaching rear flaps, formed by the attachment of the rear portion, to the exterior surfaces of the wall support assembly; attaching a third portion to a front exterior surface of the wall support assembly; and attaching front flaps, formed by the attachment of the front portion, to the exterior surfaces of the wall support assembly.

[0009] To accomplish the foregoing and related ends, certain illustrative aspects of the innovation are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles of the innovation can be employed and the subject innovation is intended to include all such aspects and their equivalents. Other advantages and novel features of the innovation will become apparent from the following detailed description of the innovation when considered in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 is an illustration of an example airflow system in accordance with an aspect of the innovation.

[0011] FIG. 2 is an illustration of the example airflow system with a cover installed in accordance with an aspect of the innovation.

[0012] FIG. 3 is an illustration of an example embodiment of an insert in accordance with an aspect of the innovation.

[0013] FIG. 4 is an illustration of an example representation of a wall support assembly in accordance with an aspect of the innovation.

[0014] FIG. 5 is an illustration of an example representation of the wall support assembly with the insert installed in accordance with an aspect of the innovation.

[0015] FIG. 6 is a flow-chart illustrating a method of installing the airflow system in accordance with an aspect of the innovation.

[0016] FIGS. 7-10 illustrate an example wall support assembly illustrating the installation of the airflow system in accordance with an aspect of the innovation.

[0017] FIG. 11 is an illustration of another example embodiment of an insert in accordance with an aspect of the innovation.

[0018] FIG. 12 is a scaled down version of a wall support assembly in accordance with an aspect of the innovation.

[0019] FIGS. 13-18 are illustrations of another example airflow system in accordance with an aspect of the innovation.

[0020] FIG. 19 is a flow-chart illustrating a method of installing the airflow system of FIGS. 13-18 in accordance with an aspect of the innovation.

DETAILED DESCRIPTION

[0021] The innovation is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the subject innovation. It may be evident, however, that the innovation can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing the innovation.

[0022] While specific characteristics are described herein (e.g., thickness), it is to be understood that the features, functions and benefits of the innovation can employ characteristics that vary from those described herein. These alternatives are to be included within the scope of the innovation and claims appended hereto.

[0023] While, for purposes of simplicity of explanation, the one or more methodologies shown herein, e.g., in the form of a flow chart, are shown and described as a series of acts, it is to be understood and appreciated that the subject innovation is not limited by the order of acts, as some acts may, in accordance with the innovation, occur in a different order and/or concurrently with other acts from that shown and described herein. For example, those skilled in the art will understand and appreciate that a methodology could alternatively be represented as a series of interrelated states or events, such as in a state diagram. Moreover, not all illustrated acts may be required to implement a methodology in accordance with the innovation.

[0024] The innovation disclosed herein provides an improved airflow system that overcomes the above mentioned disadvantages. Specifically, disclosed herein is an innovative airflow system for a residence, commercial building, etc. that utilizes the spaces formed in the wall between adjacent supports (e.g., studs) to transfer airflow from an air source (e.g., furnace, air conditioner, etc.) to an exit point (e.g., a vent, register, etc.) in a dwelling, commercial building, industrial building, etc. The improved air flow system is less costly to manufacture, store, transport install, etc. In addition, the improved airflow system is less noisy than the conventional metal ductwork system.

[0025] With reference now to the figures, FIGS. 1 and 2 illustrate one example embodiment of a scaled down model version of an example airflow system 100 in accordance with an aspect of the innovation. The airflow system 100 includes an insert 102 and a cover 104 that fits over the insert 102 to seal the airflow inside the insert 102, see FIG. 2. As will be described further below, the insert 102 fits between and attaches to adjacent supports in a wall and the cover 104 is attached to the insert 102 and, hence, the supports to form a sealed channel 106 between the adjacent supports that extends from an airflow entry point in the wall to an airflow exit point in the wall (e.g., heating/cooling vent or register).

[0026] FIG. 3 is an illustration of an example embodiment of the insert 102 in accordance with an aspect of the innovation. The insert 102 is configured to conform to a shape of a space defined between adjacent side wall supports and upper and lower wall supports (e.g., header, footer, etc.) when the insert 102 is installed. Thus, the insert 102 can be any size and as such, the insert 102 illustrated and described herein is for illustrative purposes only and is not intended to limit the scope of the innovation. In addition, the insert 102 can be made from a material configured to meet flame spread requirements, such as but not limited to a foil based material.

[0027] Prior to installation, the insert 102 is initially a substantially flat sheet of material that includes a main (back) panel 108, a first end (upper) flange 110, a second end (lower) flange 112, a first side flange 114, and a second side flange 116. The first end flange 110 and the second end flange 112 are disposed on opposite ends of the main panel 108. Similarly, the first side flange 114 and the second side flange 116 are disposed on opposite sides of the main panel 108.

[0028] The insert 102 further includes a first tab 118, a second tab 120, a third tab 122, and a fourth tab 124. The first tab 118 is disposed at a corner 126 defined by the first end flange 110 and the first side flange 114, the second tab 120 is disposed at a corner 128 defined by the first end flange 110 and the second side flange 116, the third tab 122 is disposed at a corner 130 defined by the second end flange 112 and the second side flange 116, and the fourth tab 124 is disposed at a corner 132 defined by the second end flange 112 and the second side flange 114.

[0029] The insert 102 further includes a first lip portion 134, a second lip portion 136, a third lip portion 138, and a fourth lip portion 140. The first lip portion 134 extends along an outside edge of the first end flange 110, and the first and second tabs 118, 120. The second lip portion 136 extends along an outside edge of the second end flange 112, and the third and fourth tabs 130, 132. The third lip portion 138 extends along an outside edge of the first side flange 114, and the first and fourth tabs 118, 124. The fourth lip portion 140 extends along an outside edge of the second side flange 116, and the second and third tabs 120, 122.

[0030] Still referring to FIG. 3, the insert 102 further includes multiple scored lines to facilitate the folding of the flanges and tabs during the installation process described further below. Specifically, the insert 102 includes a first scored line 142 defined between the main panel 108 and the first end flange 110, a second scored line 144 defined between the main panel 108 and the second end flange 112, a first side scored line 146 defined between the main panel 108 and the first side flange 114, a second side scored line 148 defined between the main panel 108 and the second side flange 116. A fifth scored line 150 is defined between the first end flange 110 and the first tab 118, a sixth scored line 152 is defined between the first end flange 110 and the second tab 120, a seventh scored line 154 is defined between the second end flange 112 and the third tab 122, and an eighth scored line 156 is defined between the second end flange 112 and the fourth tab 124.

[0031] The insert 102 further includes a first cut line 158 defined between the first tab 118 and the first side flange 114, a second cut line 160 defined between the second tab 120 and the second side flange 116, a third cut line 162 defined between the third tab 122 and the second side flange 116, and a fourth cut line 164 defined between the fourth tab 124 and the first side flange 114.

[0032] Referring back to FIGS. 1 and 2, the cover 104 is configured to have a similar shape to the space between adjacent wall supports such that the cover 104 seals the space to prevent air from leaking during the airflow process. The cover 104 is also made from a material configured to meet flame spread requirements, such as but not limited to a foil based material.

[0033] FIGS. 4 and 5 are illustrations of scaled down versions of an example representation of a wall support assembly 400 that will be used as an example to illustrate the insertion and attachment of the insert 102 and the cover 104 into a wall support assembly. The wall support assembly 400 can be made from any material, such as but not limited to metal, wood, etc. and can be any size. Thus, the wall support assembly 400 illustrated and described herein is for illustrative purposes only and is not intended to limit the scope of the innovation.

[0034] Still referring to FIGS. 4 and 5, the wall support assembly 400 includes a first end member 402, a second end member 404, a first side member 406, and a second side member 408. Referring also to FIGS. 3 and 6, installation of the airflow system 100 will now be described. It is to be understood that an adhesive/sealant, such as but not limited to a mastic type product (e.g., Duct-EZ), mentioned below is used to attach the insert to the each inside surface of the wall support assembly and also seals the system to reduce air leakage as compared to the conventional metal ductwork system.

[0035] At 600, the first and second side flanges 114, 116 are folded inward toward the main panel 108 along the first and second side scored lines 146, 148 such that the first and second side flanges 114, 116 are substantially flat on the main panel 108. At 602, the first end flange 110 is folded along the first scored line 142 approximately 90 degrees toward the main panel 108 such that a back surface of the first end flange 110 can be attached to an inside surface of the first member 402. At this point, the first and second tabs 118, 120 also fold in the same direction due to the first and second cut lines 158, 160. At 604, the first and second tabs 118, 120 are folded along the fifth and sixth scored lines 150, 152 respectively such that a back surface of the first and second tabs 118, 120 can be attached to an inside surface of the first and second side members 406, 408 respectively.

[0036] At 606, the second end flange 112 is folded along the second scored line 144 approximately 90 degrees toward the main panel 108 such that a back surface of the second end flange 112 can be attached to an inside surface of the second member 404. At this point, the third and fourth tabs 122, 124 also fold in the same direction due to the third and fourth cut lines 162, 164. At 608, the third and fourth tabs 122, 124 are folded along the seventh and eighth scored lines 154, 156 respectively such that a back surface of the third and fourth tabs 122, 124 can be attached to an inside surface of the first and second side members 406, 408 respectively. At 610, an adhesive/sealant is applied to a front surface of the first, second, third and fourth tabs 118, 120, 122, 124. At 612, the first and second side flanges 114, 116 are folded back away from the main panel 108 approximately 90 degrees such that a back surface of the first and second side flanges 114, 116 contact and adhere to the front surface of the first, second, third and fourth tabs 118, 120, 122, 124.

[0037] At 614, the first, second, third, and fourth lip portions 134, 136, 138, 140 are folded over a front edge of the four members 402, 404, 406, 408 respectively by approximately half the width of the front edges. At 616, the cover 104 is applied to the wall support assembly 400 and attached via the adhesive/sealant described above to prevent air leaks.

[0038] FIGS. 7-10 illustrate an example installation in accordance with an aspect of the innovation. In this example, the airflow system 100 is installed in adjacent wall support assemblies. Thus, the center support acts as both the second side member for the assembly on the left and the first side member of the assembly on the right. In one embodiment, prior to the installation of the cover 104, a metal frame 700 is attached to the support after the insert 102 is installed, as described above. The metal frame 700 is used to frame out a vent, such as a cold air return. When the cover 102 is installed as described above, the cover 104 is also attached to the metal frame 700, as shown in FIG. 8 to seal the airflow system.

[0039] FIG. 11 is an illustration of another example embodiment of an insert 1100 in accordance with an aspect of the innovation. The insert 1100 includes a first end panel 1102, a second end panel 1104, a first side panel 1106, a second side panel 1108, a first tab 1110, and a second tab 1112. Using the example wall support assembly 400 in FIG. 4, the first and second end panels 1102, 1104 attach to an inside surface of the first and second end members 402, 404 respectively. Similarly, the first and second side panels 1106, 1108 attach to an inside surface of the first and second side members 406, 408 respectively. Thus, the first and second end panels 1102, 1104 are of a similar length and the first and second side panels 1106, 1108 are of a similar length. Once installed, the tabs 1110, 1112 overlap and are sealed with the adhesive/sealant to secure the insert 1100 onto the support assembly 400. Scored lines 1114 are provided to facilitate the folding of the panels and tabs during installation.

[0040] Once the insert 1100 is installed, the cover 104 described above is attached to both the front and rear of the wall support assembly 400 as described herein to thereby form the channel to permit the air to flow from the source to the destination point.

[0041] FIGS. 12-18 illustrate another example embodiment of a scaled down model version of an example airflow system in accordance with an aspect of the innovation. The airflow system is adapted to utilize the space formed in the wall between adjacent supports (e.g., studs) to transfer airflow from an air source (e.g., furnace, air conditioner, etc.) to an exit point (e.g., a vent, register, etc.) or for a cold-air return in a dwelling, commercial building, industrial building, etc. The improved air flow system is less costly to manufacture, store, transport install, etc. In addition, the improved airflow system is less noisy than the conventional metal ductwork system.

[0042] For simplicity, the innovation will be described using a scaled down version (e.g., a model) of an example representation of a wall support assembly 1200 that will be used as an example to illustrate the airflow system and installation thereof. As mentioned above, the wall support assembly 1200 can be made from any material, such as but not limited to metal, wood, etc. and can be any size. Thus, the wall support assembly 1200 illustrated and described herein is for illustrative purposes only and is not intended to limit the scope of the innovation. The wall support assembly 1200 includes first and second side supports (e.g., studs) 1202, 1204, an upper support (header) 1206, and a bottom support (footer) 1208. The wall support assembly 1200 further includes an interior surface 1210, a first (rear) exterior surface 1212, a second (front) exterior surface 1214, a third (first side) exterior surface 1216, a fourth (second side) exterior surface 1218, a fifth (top) exterior surface 1220 (if the top exterior surface is exposed), and a sixth (if the bottom exterior surface is exposed) exterior surface 1222 (if exposed).

[0043] As will be described below with respect to FIGS. 13-18, the airflow system 1300 includes a first portion (middle interior strip) 1302 (FIGS. 13-16), a second portion (first (rear) exterior sheet) 1304 (FIGS. 16-18), and a third portion (second (front) exterior sheet) 1306 (FIGS. 17-18). Each portion 1302, 1304, 1306 of the airflow system 1300 includes a first (interior/airflow) surface 1308-2, 1308-4, 1308-6 (1308-6 is not shown but is same as 1308-4), respectively, which is a flame retardant based material (e.g. a foil based material) and a second (exterior) surface 1310-2, 1310-4, 1310-6 respectively. Thus, when installed, an interior surface (airflow surface) 1308 of the airflow system 1300 includes the first surfaces 1308-2, 1308-4, 1308-6 of each portion 1302, 1304, 1306 and thus, is configured to meet flame spread requirements. The exterior surfaces 1310-2, 1310-4, 1310-6 of each portion 1302, 1304, 1306 form an exterior surface 1310 of the airflow system 1300, may be made from a material, such as, but not limited to a foil based material, a paper based material, etc.

[0044] Referring to FIG. 13, the first portion 1302 is attached to the wall support assembly 1200 such that the exterior surface 1310-2 of the first portion is in contact with the interior surface 1210 of the wall support assembly 1200. The first portion 1302 is attached such that the first portion 1302 covers the interior surface 1210 (e.g., tucked tightly into each corner) to thereby protect the wall support assembly 1200. In addition, the first portion 1302 includes a first end 1312 and a second end 1314 and is attached to the interior surface of the wall support assembly 1200 such that the first and second ends 1312, 1314 overlap by at least two inches. Still further, a width w1 of the first portion 1302 is wider than a width w2 of each support of the wall support assembly 1200. Thus, flaps (inner flaps) 1316 are formed on the front and rear of the wall support assembly 1200. This allows the first portion to overlap the rear exterior surface 1212, the front exterior surface 1214, both the first and second side exterior surfaces 1216, 1218, and the top exterior surface 1220 of the wall support assembly 1200, as will be subsequently described.

[0045] Referring to FIGS. 14 and 15, the inner flap 1316 at each corner 1318 is slit thereby cutting the flap 1316 into inner flap segments. The flap segments are then folded and wrapped around the first and second side supports 1202, 1204, the upper support 1206 (if the top exterior surface 1218 is exposed), and the bottom support 1208 (if the bottom exterior surface 1220 is exposed) to thereby cover the rear exterior surface 1212, the front exterior surface 1214, all or a portion of both the first and second side exterior surfaces 1216, 1218, all or a portion of the top exterior surface 1220 (if exposed), and all or a portion of the bottom exterior surface 1222 (if exposed) of the wall support assembly 1200.

[0046] Referring to FIG. 16, the second portion 1304 of the airflow system 1300 is attached to the rear exterior surface 1212 such that the first surface 1308-4 is facing and covering the rear exterior surface 1212. The second portion 1304 is sized such that rear flaps 1320 extend around the first and second side supports 1202, 1204, the upper support 1206, and the bottom support 1208 to thereby cover all or a portion of both the first and second side exterior surfaces 1216, 1218, all or a portion of the top exterior surface 1220 (if exposed), and all or a portion of the bottom exterior surface 1222 (if exposed) of the wall support assembly 1200.

[0047] Referring to FIG. 17, the third portion 1306 of the airflow system 1300 is attached to the front exterior surface 1214 such that the first surface 1308-6 is facing and covering the front exterior surface 1214. The third portion 1306 is sized such that front flaps 1322 extend around the first and second side supports 1202, 1204, the upper support 1206, and the bottom support 1208 to thereby cover all or a portion of both the first and second side exterior surfaces 1216, 1218, and all or a portion of the top exterior surface 1220 (if exposed), and all or a portion of the bottom exterior surface 1222 (if exposed) of the wall support assembly 1200.

[0048] Still referring to FIG. 17, the rear and front flaps 1320, 1322 overlap on the first and second side exterior surfaces 1216, 1218, on the top exterior surface 1220 (if exposed), and on the bottom surface 1222 (if exposed) of the wall support assembly 1200. The overlaps on the first and second side exterior surfaces 1216, 1218, on the top exterior surface 1220 (if exposed), and on the bottom exterior surface 1222 (if exposed) are sealed using an adhesive/sealant, such as but not limited to a mastic type product (e.g., Duct-EZ), a spray sealant, a tape product or a combination thereof.

[0049] Still referring to FIG. 17, when the first, second, and third portions 1302, 1304, 1306 are all attached to the wall support assembly 1200, a channel 1400 is formed on an interior side (airflow side) of the wall support assembly 1200. The channel 1400 facilitates airflow to and from an airflow source (e.g., furnace, air conditioner, etc.). In addition, an interior surface of the channel 1400 is flame retardant.

[0050] Referring to FIG. 18, an opening 1800 (shown in dotted lines) may be cut into the third (front) portion 1306 of the airflow system 1300 to facilitate airflow throughout the dwelling. For example, the opening 1800 may include a vent or grill and be a cold air return to allow air flow to enter and circulate back to the airflow source. In another example, the opening 1800 may be a heating/cooling register to facilitate the heating and cooling of the dwelling, building etc.

[0051] FIG. 19 is a block diagram 1900 illustrating an installation of the example embodiment illustrated in FIGS. 12-18. At 1902, a material having a first surface 1308 and a second surface 1310 whereby at least one surface is flame retardant is provided. At 1904, the material is cut into predetermined sizes based on the size of the wall support assembly 1200. At 1906, the first portion 1302 is attached to the interior surface of the wall support assembly 1200. At 1908, slits are made in each corner 1318 of the inner flap 1316 on both the front and back of the wall support assembly 1200. At 1910, the inner flaps 1316 are folded and wrapped around and attached to exterior surfaces of the wall support assembly 1200, as described above. At 1912, the second (rear) portion 1304 is attached to the rear exterior surface 1212 of the wall support assembly 1200, as described above. At 1914, the rear flaps 1320 are folded and wrapped around the wall support assembly 1200 and attached to exterior surfaces, as described above. At 1916, the third (front) portion 1306 is attached to the front exterior surface 1214 of the wall support assembly 1200, as described above. At 1918, the front flaps 1322 are folded and wrapped around the wall support assembly 1200 and attached to exterior surfaces, as described above. At 1920, a sealant is applied to the overlapped portions to prevent air flow loss.

[0052] What has been described above includes examples of the innovation. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the subject innovation, but one of ordinary skill in the art may recognize that many further combinations and permutations of the innovation are possible. Accordingly, the innovation is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term "includes" is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term "comprising" as "comprising" is interpreted when employed as a transitional word in a claim.

Claims

1. An airflow system comprising: an insert configured to attach to wall support members to transfer an airflow from an entry point to an exit point; and a cover configured to attach to the insert and wall support members thereby providing a seal over the insert, wherein the attachment of the cover forms a channel to facilitate the transfer of the airflow.

2. The airflow system of claim 1, wherein the insert includes a main panel and a plurality of flanges that are foldable with respect to the main panel.

3. The airflow system of claim 2, wherein the insert further includes a scored line defined between the main panel and each of the plurality of flanges.

4. The airflow system of claim 3, wherein the insert further includes a plurality of foldable tabs disposed at each corner of the insert to facilitate the attachment of the insert to the wall support members.

5. The airflow system of claim 1, wherein the insert and the cover are made from a foil based material.

6. An airflow system comprising: a first portion having a first surface made from a flame retardant material and a second surface and being attached to an interior surface of a wall support assembly so that the second surface is facing the interior surface thereby covering the interior surface; a second portion having a first surface made from a flame retardant material and being attached to a rear exterior portion of the wall support assembly so that the first surface is facing the rear exterior portion thereby covering the rear exterior surface; and a third portion having a first surface made from a flame retardant material and being attached to a front exterior surface of the wall support assembly so that the first surface is facing the front exterior portion thereby covering the front exterior surface, wherein attachment of the first portion, second portion, and third portion enclose the wall support assembly and form a channel within the wall support assembly that facilitates a transfer of airflow.

7. The airflow system of claim 6, wherein the first portion has a first end and a second end that overlap when the first portion is attached to the interior surface, and wherein a width of the first portion is greater than a width of the wall support assembly such that flaps are formed on a front and rear of the wall support assembly.

8. The airflow system of claim 7, wherein slits are cut into each corner of the inner flap forming inner flap segments, and wherein the flap segments are wrapped around and attached to supports of the wall support assembly.

9. The airflow system of claim 8, wherein when attached, rear flaps from the second portion extend around and attach to supports of the wall support assembly thereby overlapping the inner flap segments.

10. The airflow system of claim 9, wherein when attached, front flaps from the third portion extend around and attach to supports of the wall support assembly thereby overlapping the inner flap segments.

11. The airflow system of claim 10, wherein the overlapping portions are sealed with a sealant.

12. The airflow system of claim 6, wherein an interior surface of the channel is made from the flame retardant material.

13. The airflow system of claim 6 further comprising an opening that facilitates airflow to or from an airflow source.

14. A method installing an airflow system comprising: providing a material having at least one flame retardant surface; attaching a first portion of the material to an interior surface of a wall support assembly; attaching inner flaps, formed by the attachment of the first portion, to exterior surfaces of the wall support assembly; attaching a second portion to a rear exterior surface of the wall support assembly; attaching rear flaps, formed by the attachment of the rear portion, to the exterior surfaces of the wall support assembly; attaching a third portion to a front exterior surface of the wall support assembly; and attaching front flaps, formed by the attachment of the front portion, to the exterior surfaces of the wall support assembly.

15. The method of claim 14, wherein prior to attaching a first portion of the material to an interior surface of a wall support assembly the method further comprising cutting the material into predetermined sizes based on a size of the wall support assembly.

16. The method of claim 14, wherein prior to attaching inner flaps, formed by the attachment of the first portion, to exterior surfaces of the wall support assembly the method further comprising cutting slits into each corner of the inner flap formed by the attachment of the first portion thereby forming inner flap segments.

17. The method of claim 16 further comprising wrapping the inner flap segments around the exterior surfaces of the wall support assembly.

18. The method of claim 14, wherein prior to attaching rear flaps, formed by the attachment of the rear portion, to the exterior surfaces of the wall support assembly the method further comprising wrapping the rear flaps around the exterior surfaces of the wall support assembly.

19. The method of claim 14, wherein prior to attaching front flaps, formed by the attachment of the front portion, to the exterior surfaces of the wall support assembly the method further comprising wrapping the front flaps around the exterior surfaces of the wall support assembly.

20. The method of claim 14 further comprising sealing overlapping portions of the inner flap, the rear flaps and the front flaps with a sealant.

Images