Air outlet louver assembly

An air outlet louver assembly (10) includes a housing (12), primary vanes (14,36), secondary vanes (48,49), and a damper door (86). A control handle (58) independently controls the primary and secondary vanes (14,36,48,49), and a wheel (100) controls the damper door (86). Ridges (74) on a secondary vane (48) engage a control fork (66) on the control handle (58) to provide ratcheting control of the primary vanes (14,36) by the control handle (58). A nub (82) on a secondary vane (48) contacts depressions (80) in the housing (12) to provide ratcheting control of the secondary vanes (48,49). Frictional contact between a nub (106) on the wheel (100) and depressions (108) in the housing (12) provide ratcheting control of the damper door (86).

TECHNICAL FIELD 
The subject invention relates to an air outlet louver assembly for 
providing incremental adjustment of the direction and volume of airflow 
therefrom. 
BACKGROUND ART 
Air outlet louver assemblies are commonly used in automobile ventilation 
systems to permit a user to adjust the direction and volume of airflow 
into a passenger compartment of an automobile. Louver assemblies generally 
include one or two sets of directional vanes that are pivotally disposed 
within a housing and at least one control handle to adjust the position of 
the vanes within the housing. In addition, many louver assemblies include 
a damper door that pivots within the housing to adjust the volume of 
airflow through the housing. 
To improve the ease with which a user can adjust the vanes, many louver 
assemblies include a positioning device to provide intermittent frictional 
resistance to movement of the vanes and create spaced rest locations for 
the vanes. In other words, two-way ratcheting control is provided to 
improve the "feel" of a control handle during adjustment of the vanes. The 
ratchet device thus makes it easier for a user to adjust the vanes in 
discrete increments and also maintains the vanes in their selected 
position in spite of any bumps or jarring motion received by the 
automobile. 
For example, U.S. Pat. No. 3,861,281 to Godwin illustrates an outlet louver 
of this type. The louver includes a plurality of directional vanes 
pivotally disposed within a first housing for adjusting the horizontal 
direction of airflow when moved. In addition, the first housing pivots 
within a second housing to adjust the vertical direction of airflow. The 
first housing includes a plurality of ridges along an outer surface 
thereof in sliding frictional contact with an arm extending from the 
second housing. In this manner, ratcheting control is provided for the 
pivotal movement of the first housing within the second housing. 
However, in Godwin U.S. Pat. No. 3,861,281 the first housing extends 
outwardly from the second housing upon pivotal movement with respect to 
the second housing. In addition to providing a potential hazard to 
passengers, extension of the first housing outside of the second housing 
disrupts the aesthetic contour of the dashboard. To avoid these problems, 
modern outlet louver assemblies utilize a single housing including two 
sets of directional vanes disposed for pivotal movement within the 
housing. This eliminates the need for pivotal motion of the first housing 
because the two sets of directional vanes provide complete directional 
control of the airflow. However, ratcheting contact between a first and 
second housing is precluded with only one housing. 
To solve this problem, ratcheting systems for single-housing outlet louvers 
have been designed. U.S. Pat. No. 3,735,691 to Gofton et al. illustrates 
an outlet louver of this type. The louver includes a housing 12 and a 
plurality of vanes 36 pivotally disposed therein. A gang bar 48 is 
attached to each of the vanes 36 for joining the vanes in coupled pivotal 
motion within the housing 12. Ratchet teeth 52 on the gang bar 48 interact 
with grooves 26 on the housing to provide ratcheting control of the vanes 
36. However, the Gofton U.S. Pat. No. 3,735,691 ratchet system will not 
work in systems without a gang bar 48, such as those with only one 
directional vane. In addition, the gang bar 48 must be located immediately 
adjacent the housing 12, reducing design options for the outlet louver. 
SUMMARY OF THE INVENTION AND ADVANTAGES 
The present invention provides an air outlet louver assembly for providing 
incremental and accurate adjustment of the direction and volume of airflow 
therefrom. The assembly includes a housing and a vane mounted within the 
housing for pivotal movement about an axis for controlling the direction 
and flow of air out of the housing. The invention is characterized by 
ratchet pawl means disposed on said vane for moving together with said 
vane in coupled rotation about said axis and for frictionally engaging a 
ratchet surface to intermittently resist movement of said vane and 
establish a plurality of spaced rest locations for said vane. 
The present invention is advantageous by providing ratcheting control 
directly between the vane and the housing. In this manner, ratcheting 
control can be provided for a system that does not include a gang bar, 
such as a one-vane system. In addition, ratcheting control can be provided 
for a system that does not include relative movement between first and 
second housings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
The present invention provides an air outlet louver assembly 10 for 
providing incremental and accurate adjustment of the direction and volume 
of airflow therefrom. The assembly 10 includes a housing 12, a vane 14,48 
mounted within the housing 12 for pivotal movement about an axis A,B for 
controlling the direction and flow of air out of the housing 12, and a 
ratchet pawl means 20,20' disposed on the vane 14,48 and pivotal about the 
axis A,B for frictionally intermittently resisting movement of vane 14,48 
with respect to the housing 12 to establish a plurality of spaced rest 
locations for the vane 14,48. 
As shown in FIG. 1, the housing 12 is a substantially rectangular member to 
be mounted within an opening in a dashboard of an automobile or other 
vehicle (not shown). The housing 12 includes a plurality of mounting 
brackets 22 which provide convenient mounting locations for attaching the 
housing 12 to the dashboard. In addition, a plurality of mounting flanges 
24 extend beyond the opening in the dashboard and prevent the housing 12 
from moving forward through the opening. The housing 12 includes a front 
opening 26 and a rear opening 28 as shown in FIG. 5. The rear opening 28 
is placed within an air source (not shown) of slightly larger diameter 
than the rear opening 28. A foam strip 30 is placed about the housing 12 
adjacent the rear opening 28 to provide a tight seal between the rear 
opening 28 and the air source. 
The housing 12 also includes a window vent 32 disposed adjacent the front 
opening 26 as illustrated in FIG. 1. The window vent 32 includes a 
plurality of fixed vanes 34 for directing air laterally with respect to 
the housing 12. By mounting the housing 12 in the dashboard adjacent a 
window (not shown), the window vent 32 directs air toward the window 
independently of the orientation of the vane 14,48. Thus, when necessary, 
a small quantity of air can be strategically directed toward the window to 
defrost the window and permit a driver to see through the window. 
As shown best in FIG. 4, a primary control vane 14 is disposed within the 
housing 12 for pivotal movement about a first axis A. In addition, two 
primary directional vanes 36 are each pivotally disposed within the 
housing 12 about discrete axes of rotation A' parallel to the first axis 
A. The primary vanes 14,36 each include two pivot studs 38 for mounting 
within holes 40 in the housing 12. The studs 38 provide pivot points for 
the primary vanes 14,36 with respect to the housing 12 and define the 
parallel axes of rotation A,A' for each primary vane 14,36. 
A primary coupling means 42 for joining the primary vanes 14,36 in coupled 
rotation about the parallel axes of rotation A,A' is attached to each 
primary vane 14,36. The primary coupling means 40 comprises a primary gang 
bar 44 including three pivot holes 46 therein. Each primary vane 14,36 
includes a pivot stud 38 disposed through the pivot holes 46. Accordingly, 
pivotal motion initiated by one of the primary vanes 14,36 is transmitted 
through the primary gang bar 42 to the remaining primary vanes 14,36. 
Therefore, identical motion in all three primary vanes 14,36 is produced 
by actuating only one of the primary vanes 14,36. 
A secondary control vane 48 is disposed within the housing 12 for pivotal 
movement about a second axis B offset from the first axis A for 
controlling the direction and flow of air out of the housing 12. 
Furthermore, six secondary directional vanes 49 are each mounted within 
the housing 12 for pivotal movement about a discrete axis B' parallel to 
the second axis B. The axes of rotation B,B' of the secondary vanes 48,49 
are non-parallel with the axes of rotation A,A' of the primary vanes 
14,36. More specifically, the secondary vanes 48,49 pivot about vertical 
axes of rotation B,B' while the primary vanes 14,36 pivot about horizontal 
axes of rotation A,A'. As shown in FIGS. 3 and 4, the secondary vanes 
48,49 each include two pivot studs 38 for mounting within holes 40 in the 
housing 12. The studs 38 provide pivot points for the secondary 
directional vanes 48,49 with respect to the housing 12 and define the 
parallel axes of rotation B,B' for each secondary vane 48,49. 
A secondary coupling means 50 operates in similar fashion to the primary 
coupling means 42 discussed above and joins the secondary vanes 48,49 in 
coupled rotation about the parallel axes of rotation B,B'. The secondary 
coupling means 50 comprises a secondary gang bar 52 including seven 
C-shaped retaining clips 54. Each secondary vane 48,49 includes a pivot 
bar 56 which snaps into a retaining clip 54 in pivotal engagement 
therewith. In this manner, pivotal motion initiated by one of the 
secondary vanes 48,49 will be transmitted through the secondary gang bar 
52 to the remaining secondary vanes 48,49. Therefore, identical motion in 
all seven secondary vanes 48,49 can be produced by actuating only one of 
the secondary vanes 48,49. 
A ratchet pawl means 20 is disposed on the primary control vane 14 and 
includes a control handle 58 operatively engaged with the primary control 
vane 14 and slidably disposed thereon. In the preferred embodiment, the 
control handle 58 comprises a top section 62 and a bottom section 64 which 
snap fit together around the primary control vane 14 to connect and retain 
the control handle 58 thereabout. The ratchet pawl means 20 further 
includes a projection 66 extending from the primary control vane 14. 
Specifically, a control fork 66 is provided on the control handle 58 which 
straddles the secondary control vane 48 to connect the control handle 58 
to the secondary control vane 48. The control fork 66 comprises two 
resilient arms 67 biased against the secondary control vane 48 in 
frictional contact therewith. 
As illustrated in FIG. 3, a ratchet surface 68 is disposed along an edge of 
one of the secondary vanes 48 in slidable contact with the ratchet pawl 
means 20. Specifically, the control fork 66 straddles the ratchet surface 
68 in slidable frictional contact therewith. As the primary control vane 
14 pivots about the first axis A, the control handle 58 and control fork 
66 also pivot in coupled rotation with the primary control vane 14 about 
the first axis A. The ratchet surface 68 includes a control bar 70, and a 
cavity 72 is disposed in the secondary vane 48 underneath the control bar 
70. In this manner, the control fork 66 extends through the cavity 72 upon 
pivotal movement of the secondary vanes 48,49. 
The ratchet surface 68 includes a plurality of ridges 74 disposed 
circumferentially about the control bar 70 at spaced intervals. 
Accordingly, the ratchet surface 68 includes a plurality of spaced 
depressions 76 disposed in intermittent frictional contact with the 
resilient arms 67 on the control fork 66. The depressions 76 comprise 
valleys disposed between the ridges 74 on the ratchet surface 68. The 
ridges 74 provide intermittent, cyclical frictional resistance to movement 
of the control fork 66 and control handle 58 against the control bar 70 
and create staggered rest locations 76 for the control fork 66 between 
each ridge 74. The ridges 74 produce a "clicking" sound and an 
accompanying vibration through the control handle 58 during movement 
thereof, providing a user with additional sensory inputs to aid in 
controlling the movement of the control handle 58. 
A ratchet pawl means 20' is also provided on the secondary control vane 48 
for frictionally intermittently resisting movement of the secondary vanes 
48,49 with respect to the housing 12 to establish a plurality of spaced 
rest locations for the secondary vanes 48,49. The ratchet pawl means 20' 
comprises a projection, or more specifically a resilient arm 84, integral 
with the secondary control vane 48 and extending therefrom. The resilient 
arm 84 includes a hub 82 disposed on a distal end thereof in slidable 
frictional contact with the housing 12. As the secondary control vane 48 
pivots about the second axis B, the resilient arm 84 and nub 82 also pivot 
in coupled rotation with the secondary control vane 48 about the second 
axis B. 
A ratchet surface 85 is disposed on the housing 12 in slidable contact with 
the ratchet pawl means 20'. The ratchet surface 85 includes a plurality of 
spaced depressions, or more specifically dimples 80, disposed in 
intermittent frictional contact with the nub 82 on the resilient arm 84. 
Because the secondary vanes 48,49 generally pivot in an arcuate path with 
respect to the housing 12, the spaced depressions 80 are disposed in an 
arcuate manner along the housing 12 to follow the arcuate path of the 
secondary nub 82 on the secondary control vane 48. 
The secondary nub 82 comprises a hemispherical projection extending from 
the secondary control vane 48 and is subject to intermittent, cyclical 
frictional resistance when moved across the housing 12 against the 
depressions 80. As will be appreciated, the secondary nub 82 may take 
other formations, such as frustoconical. The resilient, or spring loaded, 
arm 84 extending outwardly from the secondary control vane 48 biases the 
nub 82 against the housing 12. As the secondary nub 82 travels along the 
housing 12, the depressions 80 provide areas of low potential energy for 
the secondary nub 82. In other words, the depressions 80 provide a series 
of spaced rest locations for the secondary nub 82. As the secondary nub 82 
moves between depressions 80, however, the arm 84 biases the secondary nub 
82 in frictional contact with an edge of each depression 80 and with the 
housing 12. In similar fashion to the ratchet pawl means 20, this 
intermittent frictional resistance produces a "clicking" sound and 
accompanying vibration which will aid a user in controlling the movement 
of the secondary vanes 48,49. 
A damper vane 86 is mounted within the housing 12 for pivotal movement 
about a third axis C to control the volume of airflow through the outlet 
louver assembly 10. The damper vane 86 is shown best in FIG. 4 and 
comprises a top plate 88, a bottom plate 90, a foam pad 92 sandwiched 
between the plates 88,90, two pivot studs 38, and a control arm 94. The 
pivot studs 38 are disposed within holes 40 in the housing 12 to provide 
pivotal motion of the damper vane 86 within the housing 12. As shown in 
FIG. 5, the foam pad 92 provides a flexible seal between the housing 12 
and the damper vane 86 to further restrict the airflow through the housing 
12. As shown in FIG. 2, the control arm 94 extends through a groove 96 in 
the housing 12 to guide and limit the arcuate travel of the damper vane 86 
within the housing 12. 
The damper vane 86 includes a damper control means 98 shown in FIG. 2 for 
controlling the relative position of the damper vane 86 with respect to 
the housing 12. The damper control means 98 includes a damper control 
handle 100, or wheel, rotatably disposed within the housing 12. A control 
lever 102 comprising a resilient arm extends from the control handle 100 
in slidable frictional contact with the housing 12. The control lever 102 
is operatively engaged with the control arm 94 on the damper vane 86 such 
that actuation of the damper control handle 100 produces corresponding 
movement in the damper vane 86. 
The damper control means 98 includes a damper ratchet pawl means 104 
disposed on the damper control handle 100 for frictionally intermittently 
resisting movement of the damper control handle 100 with respect to the 
housing 12 to establish a plurality of spaced rest locations for the 
damper control handle 100. The damper ratchet pawl means 104 includes the 
control lever 102 and a damper nub 106 disposed on the control lever 102 
extending toward the housing 12 in slidable contact therewith. A plurality 
of spaced dimples 108 are disposed on the housing 12 in slidable, 
intermittent frictional engagement with the damper hub 106. In similar 
fashion to the secondary positioning means 78, the damper hub 106 and 
depressions 108 coact to provide intermittent, cyclical frictional 
resistance to movement of the damper vane 86. The resilient control lever 
102 provides a biasing force to place the damper nub 106 in frictional 
engagement with the depressions 108. 
In operation, the position of the primary vanes 14,36 is adjusted by moving 
the control handle 58 vertically. This causes the primary vanes 14,36 to 
pivot with respect to the housing 12, as well as produce a corresponding 
movement in the control fork 66 across the ridges 74 on the control bar 68 
and provide a two-way ratcheting effect. The ratcheting action does not 
perform in the traditional sense because the primary vanes are still 
moveable in two directions. The ratcheting means 20 merely provides 
intermittent frictional resistance to movement of the primary vanes 14 to 
improve the "feel" during adjustment of the primary vanes 14. 
A user can also independently adjust the secondary vanes 48 by sliding the 
control handle 58 horizontally along the primary control vane 14. This 
causes the control fork 66 to move horizontally against the control bar 68 
and force the secondary vanes 48,49 to pivot with respect to the housing 
12. As the secondary vanes 48,49 pivot, the secondary nub 82 provides a 
two-way ratcheting effect against the spaced depressions 80 in the 
housing. Similarly, actuation of the wheel 100 produces two-way ratcheting 
action of the damper vane 86 within the housing 12 as the damper nub 106 
engages with the dimples 108 in the housing 12. 
The invention has been described in an illustrative manner, and it is to be 
understood that the terminology which has been used is intended to be in 
the nature of words of description rather than of limitation. 
Obviously, many modifications and variations of the present invention are 
possible in light of the above teachings. It is, therefore, to be 
understood that within the scope of the appended claims wherein reference 
numerals are merely for convenience and are not to be in any way limiting, 
the invention may be practiced otherwise than as specifically described.