Abstract:
Apparatus for a discharge vent on an air circulation system includes structures for controlling the direction and quantity of airflow. Filter elements may be provided to help reduce contaminants that might otherwise be discharged through the vent. Preferred methods for assembling and using the apparatus are disclosed.

Description:
The present invention relates to an apparatus for regulating air and removing contaminants from air discharge vents, such as those used for air conditioning or heating systems. 
     BACKGROUND OF THE INVENTION 
     Central heating and air conditioning systems typically include ducts to distribute processed (heated or cooled) air. These ducts distribute heated or cooled air from the source units (either a heater or air conditioner). In many office buildings and similar environments, the ducts are positioned above suspended ceilings and are configured to discharge the treated air through spaces that would otherwise be filled with removable ceiling panels. 
     Vents or grilles of various configurations may be positioned at these discharge “panel” locations. Much of the background and relevant problems associated with those vents or grilles are discussed in my U.S. Pat. No. 5,564,975 for AIR FLOW CONTROLLER FOR HEATING AND AIR CONDITIONING VENTS. 
     Although my invention of U.S. Pat. No. 5,564,975 addresses many of the shortcomings of the prior art, further refinements and other approaches discussed below provide alternatives that may be beneficial in some or many installations. 
     In addition, even for systems that may provide some airflow adjustability for the convenience and comfort of the occupants, most discharge vents do not have air filters to filter out dust, bacteria or other contaminants. Where filters are used, it is more common to find them on air returns or air handlers, which typically feed air to the intake side of air conditioning or heating units. While such filtering is helpful, the filters sometimes can be difficult to service and in any case cannot do anything to reduce contamination that may exist or be generated within the ducting system itself. Thus, dust or other contaminants in the duct or generated by the heater/air conditioner are commonly blown onto occupants or back into the buildings, rather than being filtered out. 
     Part of the problem associated with air ducts relates to moisture that occurs naturally as part of the heating/air conditioning process. Typically in air conditioning systems, when air is cooled, some of the moisture condenses along the walls of the ducts. That moisture not only causes dust and other things to accumulate along the ducts, but permits and enables microscopic growths to appear and accumulate (such as mildew, fungus, bacteria and other microbial particles). The typical air filter at the system return/intake does nothing to stop the system from blowing these potentially harmful microbes onto occupants of the building. 
     Warren Technology&#39;s Uni Guard™ individual room air filtration system addresses some of those concerns but has several shortcomings. Among other things, its diffuser provides a limited range of control flexibility, and replacing its filter typically requires removing one or more adjacent ceiling tiles, which typically is at least somewhat inconvenient and time consuming. 
     My U.S. Pat. No. 5,564,975 likewise addresses some of the foregoing issues, but is somewhat limited as to the “degree” of airflow control it provides. Moreover, it does not address the contaminants issue. 
     Other prior art patents (such as U.S. Pat. No. 3,690,243 to Lambert, U.S. Pat. No. 3,757,667 to Lambert, U.S. Pat. No. 4,506,828 to Grant, U.S. Pat. No. 4,417,687 to Grant, U.S. Pat. No. 4,375,183 to Lynch, Reissue patent 30953 of U.S. Pat. No. 4,231,513 to Noll et al., U.S. Pat. No. 4,231,253 to Faith et al., and U.S. Pat. No. 3,699,871 to Larkfeldt) have similar shortcomings. In addition, the devices in those patents typically are not easy to install or easy to use, and commonly are more expensive to produce and/or install and maintain. In addition, they do not teach nor contemplate using filter elements. 
     An effective solution should not only address the foregoing flow and contaminants issues, but should also be easy to use and replace, be reasonably priced, and be provided for both retrofits and new installations. 
     OBJECTS AND ADVANTAGES OF THE INVENTION 
     Accordingly, it is an object of the present invention to provide an improved air flow controller for heating and air conditioning vents. 
     It is a more particular object of the present invention to provide a vent with multiple flow paths wherein each individual flow path may be separately regulated. 
     It is another object of the present invention to provide an air flow controller with vent flow paths that are easy to manipulate. 
     A further object of the present invention is to provide a vent with flow paths that can be adjusted from a distance when using a stick or similar reaching apparatus. 
     Yet another object of the invention is to provide a vent with filter elements for removing contaminants. 
     A still further object of the present invention is the provision for allowing filter elements to be readily replaced, such as without having to move or remove any adjacent ceiling tiles. 
    
    
     Other objects and advantages of the invention will be apparent from the following specification and the accompanying drawings, which are for the purpose of illustration only. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an isometric view of a preferred embodiment of the invention, as installed on a suspended ceiling and with the side vents in a partially open position. 
     FIG. 2 is similar to FIG. 1, but illustrates the lower deflector panels in an open position and the side vents in a closed position. 
     FIG. 3 is an exploded view of the embodiment of FIGS. 1 and 2, including a filter element. 
     FIG. 4 is an isometric view of a preferred embodiment separate from the suspended ceiling structure and including a filter element. 
     FIG. 5 is an exploded view of an alternative view of a filter element assembly useful in the invention, similar to the filter assembly portion of FIG. 4 except for the cross-sectional shape of the mounting brackets. 
     FIG. 6 is similar to FIG. 5, but shows the assembly of FIG. 5 in an isometric view with the filter element seated within the mounting brackets. 
     FIG. 7 is a foreshortened cross-sectional view along reference line  7 — 7  of FIG.  4 . 
     FIG. 8 is an isometric view of an alternative embodiment of the invention. 
     FIG. 9 is similar to FIG. 8, and illustrates in a partially exploded isometric view the alternative embodiment of FIG. 8 installed in a preferred support structure, as it might appear when the lower portion is hinged downwardly to permit replacement of filters or other service. 
    
    
     DESCRIPTION OF PREFERRED EMBODIMENT 
     The drawings illustrate a preferred embodiment of the invention, including an improved air flow controller  1 . Preferably, the components of the air flow controller  1  are fabricated from suitably strong, lightweight materials to provide reliable service in an air exhaust system and are easy to transport and install. Many of the components may be fabricated by injection molding, blow molding, extruding plastic, or similar processes. In embodiments using separate components to complete the assembly, that assembly of various pieces to each other may be accomplished by any suitable means, including without limitation gluing, welding, screws, etc. Preferably, most of the mechanical components of the invention are extruded from plastic, injection molded from glass-filled reinforced nylon, or fabricated by some similar process, including (without limitation) using extruded aluminum or other metal. Persons of ordinary skill in the art will understand that the invention may be effectively practiced with a wide variety of materials and fabrication methods. 
     As mentioned above, much of the background associated with suspended ceiling and related vents or grilles are discussed in my U.S. Pat. No. 5,564,975, the disclosures of which are incorporated herein by reference. In FIG. 1 of the present document, the preferred apparatus  1  includes a pair of elongated channels or rails  2 , each having a side  6  surface that is machined or fabricated to include a regulating vent or rail slot  4 . The regulating vent or rail slot  4  is preferably an elongated opening in the side  6  of the channel  2 . However, persons of ordinary skill in the art will understand that the regulating vent  4  can be of any of a wide variety of configurations and dimensions and numbers of holes in the side  6 , so long as the structural integrity of that channel  2  is not compromised. In their open position (see FIG.  1 ), the preferred regulating vents  4  on each of the channels  2  provides a first pair of flow paths within a first flow plane  42 . 
     In the preferred embodiment, the apparatus  1  is installed in a suspended tile ceiling or hanging ceiling. The preferred connection of channels  2  to the ceiling is further discussed below regarding FIG.  7 . In general, a series of ceiling rails or ceiling splines ( 30 ,  32 ,  34 , and  36 ) in the shape of T-bars are suspended on cables attached to a higher ceiling (not shown). The ceiling rails, (sometimes referred to herein as just “rails”), typically have seating surfaces (their T portion), whereby ceiling tiles seat. Lights, air ducts, air vents and other fixtures may be hung within the T-bar framework provided by the rails but those elements typically terminate above the T-bar rails. The preferred embodiment of apparatus  1  is suspended from the rails but protrudes below the rails. Although T-bars are discussed herein, ceiling rails with other cross-sections can be used in practicing the invention. 
     Preferably, each of the elongated channels  2  is fixedly connected to one of the parallel ceiling rails  30  and  32  via one or more clips  68  (see FIG.  7  and related discussion below). Alternatively, and where ceiling rails are difficult to get to or are not used (such as the case with plaster ceilings and seamless ceiling tiles), the apparatus can be attached using screws, double sided tape, or similar methods. In the preferred assembly process, the support brackets  64  are first attached to the channels  2 . The channels are then mounted onto the ceiling rails  30  and  32 , and then other components may be assembled to form the overall apparatus  1 . As shown in FIG. 1, the apparatus  1  includes a pair of slidable (deflector) panels  50  and a pair of slidable dampers  10 . The slidable panels  50  are slidably positioned along the lower half of the elongated channels  2 , the lower lip  8  (see also FIG.  4 ), and serve as regulators for another of the air flow paths  46  (illustrated as generally downward). The slidable dampers  10  preferably are in a tongue and groove engagement with the elongated channels  2  and serve as the regulators for the first pair of regulating vents  4 . The preferred manner and way in which the dampers  10  and panels  50  are connected to the elongated channels  2  are further discussed below in FIG.  7 . 
     When the slidable panels  50  are in the closed position, as shown in FIG. 1, or otherwise partially block the flow of air along path  46 , air flow is diverted along the first plane  42  not only towards and through the vents  4  (if those are uncovered as explained herein), but also may be diverted through a second pair of vents  12  formed by the space between the panels and the tile ceiling  40 . In the preferred embodiment, vents  12  are not provided with separate covers but instead remain “open” at all times. 
     When the panels  50  are in the closed position and the slidable dampers are in the open position, as shown, exhaust air from the air duct flows along plane  42 , out of the first pair of regulating vents  4  and the second pair  12 . In this configuration, air flow may be regulated along plane  42  by sliding the dampers  10  along the tongue and groove race and the slidable panels along the seat of the elongated channels  2 . By covering the vents  4  partially or totally, more or all of the flow in plane  42  can be forced out the aforementioned spaces between the panels  50  and the ceiling  40 . 
     If instead, an occupant wishes to direct some or all of the flow downwardly, this can be achieved by sliding the panels  50  away from their “closed” position, FIG. 2, illustrated as being centered under the air duct opening. When that is done, some or all of the center regulating vent  14  is exposed, thereby allowing air flow to flow downwardly therethrough, in direction  46 . In the preferred embodiment, two of the sides of the center regulating vent  14  are generally formed by the elongated channels  2 , and the other two sides by the edges of the slidable panels  50  (depending on whether those edges underlie the air flow path). In certain installations and applications, when slidable panels  50  are fully opened, the interior edges of the panels  50  may be outside the air flow path, so that the edges of the ceiling rails  34  and  36  or some other structure delimits the other two sides of the center regulating vent  14 . As indicated above, air flow through regulating vent  14  is in the direction of arrow  46 , FIG.  2 . 
     The particular flow path of air (through the combination of vent  14 , vents  4 , and vents  12 ) depends on a number of factors, including the air pressure at the duct, the settings of the various panels  50  and slides  10 , etc. Persons of ordinary skill in the art will understand that the relative size and number of slidable panels  50  and dampers  10  can be any of a wide selection, to provide additional fine-tuning to the flow control achievable with the invention. Likewise, the size and position of the other components may vary depending on the particular application and range of use desired. 
     In the preferred embodiment, the panels  50  are fabricated with a clear translucent material. One of the reasons for this preferred embodiment is occasionally the apparatus  1  is placed next to or near a set of ceiling lights. If slidable panels  50  are moved to the open position, as shown in FIG. 2, the panels  50  may obstruct the paths of the ceiling lights (if those are adjacent to the apparatus  1 ), unless the panels  50  are of a translucent material, in which case, the lights simply illuminate on through. 
     Adjusting and positioning the slidable panels  50  and the slidable dampers  10  to regulate air flow can be done in any suitable manner. In the preferred embodiment, for example, an individual  58  can pick up a stick or other elongated rod-like member  56  and easily move the panels  50  and dampers  10  to any desired combination of positions. The apparatus  1  is preferably fabricated with materials and within dimensional tolerances such that the panels  50  and the dampers  10  can be move with minimal force. Preferably, fins  15  are provided on each of the dampers  10  to serve as leverage points for the occupant&#39;s stick  56  when the occupant  58  manipulates the dampers  10 . 
     Further details of the preferred embodiment are illustrated in FIG.  3 . The elongated channels  2  are fabricated with several tongues and grooves, e.g.,  70  and  72 , to which other components may be engaged. Preferably, the ends of each of the elongated channels  2  include stop members  52 . In the preferred embodiment, the stop members  52  are L-brackets or angle brackets, and are connected to the ends of the channels  2  using general bonding agents or glue. However, those person of ordinary skill in the art will understand that any other suitable method (including, by way of example, screws or rivets or sonic welding) may be used without departing from the invention. 
     Among other things, the stop members  52  provide a stop point for the sliding dampers  10  and panels  50 . The preferred dampers  10  include a downwardly protruding tongue element  61 , FIG. 3, which interferingly contacts the stop members  52  to prevent it from being slid off the channel  2 . Similarly, the stop members  52  act to stop the panels  50  from being slid out of engagement with the assembly  1 , via the preferred stop tabs  54  (see FIG. 3) affixed to or formed on the panels  50  that interferingly contact the downwardly extending portions  53  of the stop members  52 . The stop members  52  ensure that when the panels  50  and the dampers  10  are moved to the open position, they are not accidentally disengaged from the elongated channels  2 . 
     In the preferred embodiment, the apparatus  1  includes a pair of support brackets  64 . The preferred support brackets  64  have at least two functions: to support the filter element  60  (preferably by it resting on the inwardly extending portions  66 ) and to attach the entire apparatus  1  onto the T-bars of the ceiling rails  30  and  32 , using the clip portions  68 . For this latter function, the support brackets  64  preferably act as mounting means. The support brackets  64  can be provided in any convenient length, and multiple shorter pieces (rather than a single long continuous piece  64 ) can be used where necessary or desired. As further discussed in connection with FIG. 7, the preferred support brackets  64  use a tongue and groove  65  and  74  engagement with the elongated channels  2 . 
     Although various embodiments of the invention may be practiced with no filter element, and although a wide variety of filter can be effectively used in the invention, the preferred filter element  60  is of a woven type surrounded by mesh metal frames and a cardboard perimeter  62  as bonding agent, as often found in a local hardware store. The cardboard edges must be sufficiently narrow to seat along the support channels  66  of the support brackets  64 . In an alternative embodiment, not shown, the filter element  60  comes in two or more separate pieces. Each piece consists of a metal frame, similar to three rectangles back-to-back-to-back, enwrapped by fiber materials. Persons of ordinary skill in the art will understand that as filter technology changes and improves, different filters may be used without deviating from the spirit of the invention. 
     FIG. 4 depicts a fully assembled apparatus  1  separate from the preferred suspended ceiling structure. The preferred embodiment of apparatus  1  does not include lateral connections (other than the aforementioned suspended ceiling rails) to hold the elongated channels  2  in position, as shown, and to form a rectangular frame. This helps reduce cost and weight, and simplifies installation. Persons of ordinary skill in the art will understand that, for certain applications, lateral supports (such as two additional perpendicular channels) can be utilized without deviating from the spirit of the invention. 
     In the preferred embodiment, the stop members  52  are glued to the ends of the channels  2  at the factory. In other words, they are shipped with the stop members  52  bonded in their respective positions. Alternatively, the stop members can be shipped separately and glued by the end users. This gluing can take place before or after the dampers  10  and support brackets  64  are engaged with the channels  2  (via the various tongues and grooves). Each channel  2  is then clipped into position by snapping clip member  68  over the T of the ceiling rail. Thus, support brackets  64  are preferably first installed onto the channels  2  before the channels are installed onto the ceiling rails. After both channels  2  are clipped in position, they hang along the ceiling by the clip members  68 . The ceiling rails  34  and  36  then, See FIG.  1  and FIG. 2, can be viewed as lateral structures that help form an overall operative sturdy rectangular shape for the apparatus  1 . 
     Preferably, after the channels  2  are in position, the filter element  60  is installed. Although the filter element  60  can be positioned and retained within the assembly in any suitable manner, preferably one of the sides is first wedged into one of the support brackets  64 , and then the other support bracket  64 , along with the other channel  2 , is temporarily deflected or bent slightly outwardly so that the other side of the filter can be pushed up into position. Among many alternative methods, the components can be assembled by doing nothing to the support brackets  64  and channels  2 , but instead bending (arched or otherwise deformed) slightly at the center of the filter  60 , so that the filter can be wedged into position along the seats  66  of the support brackets  64 . The preferred filter element  60  completely “filters” airflow from the duct through vent  14  (in direction  46 ). Slidable panels  50  are installed next. Similar to the filter, the panels  50  are preferably temporarily bent slightly at their center points so that they can be wedged into position and engagement with the seats or lower lip  8 . As indicated above, the preferred panels  50  and dampers  10  are slidably adjustable to accommodate the needs and comfort of the occupant or occupant in the area of the air duct. 
     FIG. 5 is an exploded view of an alternative embodiment of the support brackets or mounting means  64  and the filter element  60 . FIG. 6 is an isometric view of the same components as in FIG.  5 . In the embodiment of FIGS. 5 and 6, the channels  2  are similarly attached to the ceiling rails via clip elements  68 . In that embodiment, filter element  60  would preferably merely rest along the seats instead of being wedged into the support brackets  64 . In such an arrangement, some small percentage of the exhaust air might be more likely to pass around the filter (i.e., not get filtered) than with the “wedged” embodiment shown in FIGS. 4 and 7. FIG. 7 is a cross-sectional view of the apparatus  1  taken from FIG.  4 . As earlier discussed, the preferred embodiment of apparatus  1  includes various channels and brackets in tongue and groove arrangements. Preferably, the two elongated channels  2  are symmetrically identical to one another. For purposes of this disclosure and description, only one of the channels therefore needs to be discussed. At the outer edge of the preferred channel  2  are upper and lower lips or tongues  70  to engage lips  16  of the damper  10 . The support bracket  64  is similarly engaged with the channel  2 . The upper seat  76  works in tandem with the lower lip  65  on the support bracket  64  to engage the channel  2  about the channel surface  78  and the groove  74 . The clip element  68 , as shown, is provided to clip onto the T-bar of the adjacent respective ceiling rail (such as rail  30  or  32 , FIG.  1 ). Also shown in the background is the stop member  52 , with its downwardly protruding portion  53 . The filter element  60  is also shown engaged along the seat  66  of the support bracket  64 . Below the seat  66  is the slidable panel  50 , resting along the other seat  8  of the elongated channel  2 . 
     In the preferred embodiment, the apparatus  1 , shown installed in FIG.  1  and FIG. 2, can be readily used in an after market retrofit of existing air ducts. That is, where flow control and/or contaminants are problematic, the apparatus  1  may be purchased and installed in conjunction with existing structure and vents. The apparatus  1  is configured to fit under an existing vent and attach to the existing ceiling rails. The preferred apparatus  1  has clipping mechanisms such as grooves  68 , discussed elsewhere herein, to clip onto the T-bar of the ceiling rails  30  and  32 . 
     FIG. 8 illustrates one of the many alternative embodiments of the invention. The embodiment of FIG. 8 is especially useful for new installations, although it can be used to retrofit existing structures and ducting. As illustrated, the apparatus  1  includes a plenum  80  and a diffuser  90 . The plenum  80  is shown as having four distinct sides and tapering inward at the top  82 , although persons of ordinary skill in the art will understand that any suitable configuration can be utilized. Although not shown, the top  82  of the plenum preferably includes circular knock-outs of varying diameters and/or locations on the top  82 . The knockouts are typically perforated patterns in the top  82 , preferably provided in at least one diameter. Persons of ordinary skill in the art will understand that these knock-outs are useful during installation, in that an appropriate size knock-out (of the same or approximate diameter  102  as the duct  100 ) can be removed from the top  82  to engage with (or otherwise accommodate or attach to) the duct  100 . 
     Preferably, the duct  100  terminates at the knock-out line and does not protrude into the plenum interior. Persons of ordinary skill in the art will understand that other arrangements can be employed without departing from the spirit of the invention. When installed, the preferred apparatus of FIGS. 8 and 9 seats above the ceiling line, between rails  30 ,  32 ,  34 , and  36 , resting on the flange or mounting means  84 . A diffuser  90  preferably protrudes downward, into the interior environment. The preferred diffuser includes four distinct sides  96 , each side preferably having a regulating vent  92  and a vent regulator  94 . In the embodiment of FIGS. 8 and 9, each vent regulator  94  is shown with at least one vane  98 . Preferably, a plurality of vanes (three vanes per vent regulator  94  are illustrated) better regulates air flow (by providing a more focussed air flow). Preferably, the vanes  98  pivotally connect to the vent regulator  94  and the vent regulator  94  pivotally connects to the regulating vent. 
     The diffuser  90  and the plenum  80  are preferably attached to one another on one side by a hinge  110  (although multiple hinges may also be used) and on the other side by a locking means. Preferably, the locking means is a latch and lever arrangement (as further discussed in FIG.  9 ). However, persons of ordinary skill in the art will understand that other frictional or locking or detent means for temporarily engaging the diffuser  90  with the plenum  80  may be readily utilized without deviating from the spirit of the invention. 
     Although the diffuser  90  is depicted as having a generally flat surface  91 , the diffuser  90  may be provided concave upward, in the direction of the plenum, to create an optical illusion that the apparatus  1  is not protruding as far downwardly as it really is. For such concave embodiments, the surface  91  preferably is provided with a concave center point with sloping lines running to each of the corners of the diffuser  90 . 
     In the embodiment of FIGS. 8 and 9, the apparatus includes separate filter elements  60  for each of the regulating vents  92 . Alternatively, a single filter element (not shown) would be equally effective if the filter is positioned so that air flow first goes through the filter before it exits the separate vents  92 . The preferred multiple filter elements  60  are positioned directly adjacent to each of the vents  92  via filter clips  86 . Preferably, the filters  60  and the clips  86  are in frictional engagement with one another. 
     Preferably, each vent regulator  94  includes a pair of generally round pegs  114  for pivoting the vent regulator  94  and for connecting the vent regulator  94  to the diffuser  90 , via engagement with the vent sockets  116 . The pivoting action of the vent regulator  94 , with respect to the diffuser  90  permits the occupant to direct the flow  120  along several planes. For further adjustability, the vanes  98  can be provided so as to be pivotable with respect to the vent regulator  94 . In the alternative embodiment, the vanes  98  may be fixed and only the vent regulator be pivotable. 
     Preferably, the diffuser  90  hingedly opens from the plenum (and permits access to the interior thereof) by pulling down along the edge  122  of the diffuser  90  opposite the hinge. The diffuser may be locked into position, as shown in the example, via one or more latches  112  along the flange  84  and corresponding levers  124  along the diffuser. 
     As indicated above, the duct may terminate at the knock-out. In such embodiments, the duct  100  would not protrude into the plenum as shown in FIG.  9 . 
     Included in the many alternative embodiments of the invention not shown is modifying the mounting means of the apparatus to work with horizontal vents, such as are common in residential dwellings. 
     Although the preferred embodiment of the invention has been described with some specificity, the description and drawings set forth herein are not intended to be delimiting, and persons of ordinary skill in the art will understand that various modifications may be made to the embodiments discussed herein without departing from the scope of the invention, and all such changes and modifications are intended to be encompassed within the appended claims.