Patent Publication Number: US-2021172644-A1

Title: Compact diffuser

Description:
BACKGROUND 
     The present disclosure relates generally to heating, ventilation, and air conditioning systems, and in particular, to a diffuser for use in a heating, ventilation, and air conditioning (HVAC) system. 
     SUMMARY 
     The following presents a simplified summary of one or more aspects in order to provide a basic understanding of such aspects. This summary is not an extensive overview of all contemplated aspects, and is intended to neither identify key or critical elements of all aspects nor delineate the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form as a prelude to the more detailed description that is presented later. 
     In an aspect, for example, a diffuser assembly includes a housing that defines an internal chamber having an open end, a return air outlet, and a supply air inlet; a cover sized to cover the open end, wherein the cover defines a return air inlet and a supply air outlet; and an internal return air duct longitudinally extending within the internal chamber and connecting the return air inlet and the return air outlet, wherein the internal return air duct includes an inner duct surface that defines a return air chamber within the internal return air duct and an outer duct surface that defines a supply air chamber between the housing and the outer duct surface, wherein the supply air chamber defines a supply air path between the supply air inlet and the supply air outlet. 
     In another aspect, a heating, ventilation, and air conditioning (HVAC) system includes an air handling unit and a diffuser assembly connected to the air handling unit via a supply air duct and a return air duct. The diffuser assembly includes a housing that defines an internal chamber having an open end, a return air outlet, and a supply air inlet; a cover sized to cover the open end, wherein the cover defines a return air inlet and a supply air outlet; and an internal return air duct longitudinally extending within the internal chamber and connecting the return air inlet and the return air outlet, wherein the internal return air duct includes an inner duct surface that defines a return air chamber within the internal return air duct and an outer duct surface that defines a supply air chamber between the housing and the outer duct surface, wherein the supply air chamber defines a supply air path between the supply air inlet and the supply air outlet. 
     In a further aspect, a diffuser assembly kit includes a housing that defines an internal chamber having an open end, a return air outlet, and a supply air inlet; a cover sized and engageable to cover the open end, wherein the cover defines a return air inlet and a supply air outlet; and an internal return air duct longitudinally extendable within the internal chamber and connectable to the return air inlet and the return air outlet, wherein the internal return air duct includes an inner duct surface that is positionable to define a return air chamber within the internal return air duct and an outer duct surface that is positionable to define a supply air chamber between the housing and the outer duct surface, wherein the supply air chamber defines a supply air path between the supply air inlet and the supply air outlet. 
     To the accomplishment of the foregoing and related ends, the one or more aspects comprise the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative features of the one or more aspects. These features are indicative, however, of but a few of the various ways in which the principles of various aspects may be employed, and this description is intended to include all such aspects and their equivalents. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosed aspects will hereinafter be described in conjunction with the appended drawings, provided to illustrate and not to limit the disclosed aspects, wherein like designations denote like elements, and in which: 
         FIG. 1  is an exploded top left isometric view of an example diffuser assembly according to the present aspects; 
         FIG. 2  is an isometric bottom left view of the example diffuser assembly of  FIG. 1 ; 
         FIG. 3  is a left side view of the example diffuser assembly of  FIG. 1 ; 
         FIG. 4  is a front side view of the example diffuser assembly of  FIG. 1 ; 
         FIG. 5  is a cross-sectional view of the example diffuser assembly of  FIG. 1  along line  5 - 5  in  FIG. 3 ; 
         FIG. 6  is a bottom view of the example diffuser assembly of  FIG. 1 ; 
         FIG. 7  is a cross-sectional top left isometric view of the example diffuser assembly of  FIG. 1  along line  5 - 5  in  FIG. 3 ; 
         FIG. 8  is a top left isometric view of the example diffuser assembly of  FIG. 1 ; 
         FIG. 9  is a block diagram of an example heating, ventilation, and air conditioning (HVAC) system including the example diffuser assembly of  FIG. 1 ; and 
         FIG. 10  is an example schematic diagram of air flow during an operation of the example diffuser assembly of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     The detailed description set forth below in connection with the appended drawings is intended as a description of various configurations and is not intended to represent the only configurations in which the concepts described herein may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of various concepts. However, it will be apparent to those skilled in the art that these concepts may be practiced without these specific details. In some instances, well known components may be shown in block diagram form in order to avoid obscuring such concepts. 
     Aspects of the present disclosure provide a diffuser assembly including a housing that defines openings to and from an internal chamber to define a supply air path, and a internal return air duct that extends from one side of the housing to an opposing side, across the internal chamber, to define a direct return air path. In an implementation, for example, the housing includes at least a first wall connected to one or more adjacent walls to define the internal chamber, which has an open end opposite the first wall. The diffuser assembly may additionally include a cover member configured to fit on the open end and enclose the internal chamber. The cover member includes at least one first internal grill wall that defines a return air inlet, and the first wall includes an internal wall that defines a corresponding return air outlet. The internal return air duct is connected to and extends between the opposing return air inlet and the return air outlet. In some configuration, the return air inlet and the return air outlet are aligned on opposing sides of the diffuser assembly, thereby defining a direct or substantially straight return air path via the internal return air duct extending through the diffuser assembly. The one or more adjacent walls of the housing may include an internal wall that defines a supply air inlet that is in communication via the internal chamber with one or more supply air outlets defined by one or more second internal grill walls of the cover member. In some configurations, the arrangement of the supply air inlet and the one or more supply air outlets define a curved supply air path through the diffuser assembly. In some cases, the internal return air duct may be concentrically positioned within the diffuser assembly to provide a single-point air distribution system having unobstructed supply and return air flows. Thus, in an aspect, the diffuser assembly according to the configurations described herein provides a simple and efficient air diffuser, as compared to prior solutions, by having a reduced number of parts, and hence reduced manufacturing cost, and by having improved airflow paths, thereby increasing airflow efficiency and heating, ventilation, and air conditioning (HVAC) system performance. 
     In some implementations, the walls of the diffuser assembly (e.g., the walls defining the internal chamber) may be formed in a variety of shapes, such as a rectangle, a square, a circle, etc. 
     In some implementations, the internal return air duct may be configured concentrically within the housing. 
     Referring to  FIGS. 1-8  (which provide various views of an example aspect), in one non-limiting implementation, a diffuser assembly  100  has a housing  102  (also referred to as a diffuser box) with a first wall  104  connected to a set of one or more adjacent walls (e.g., a second wall  106 , etc.) to define an internal chamber  111  having an open end  107 , where the first wall  104  defines a closed end of the housing  102  opposite the open end  107  and extending substantially in a plane parallel to the open end  107 . The first wall  104  includes a first internal surface that defines a return air outlet  110 , and the second wall  106  has a second internal surface that defines a supply air inlet  112 . The diffuser assembly  100  further includes a cover member  108  having a cover body sized to cover the open end  107  and connect to the set of one or more adjacent walls (e.g., the second wall  106 ). The cover body of the cover member  108  includes a first internal grill wall defining a return air inlet  114  and a second internal grill wall defining a plurality of supply air outlets  116  surrounding the return air inlet  114 . The first wall  104  and the cover member  108  extend substantially in parallel to each other, and the second wall  106  is adjoining with and extends substantially orthogonal to both the first wall  104  and the cover member  108 . 
     The diffuser assembly further includes an internal return air duct  118  having a duct wall longitudinally extending within the internal chamber  111  and connecting the return air outlet  110  with the return air inlet  114 , thereby defining an unobstructed and substantially straight return air path  115  ( FIG. 5 ). The duct wall of the internal return air duct  118  includes an inner duct surface  121  that defines a return air chamber  119  within the internal return air duct  118  and an outer duct surface  103  that defines a supply air chamber  105  between the housing  102  and the outer duct surface  103 , where the supply air chamber  105  defines a supply air path  117  ( FIG. 5 ) between the supply air inlet  112  and the supply air outlets  116 . 
     In an aspect, for example, the supply air outlets  116  may include one supply air outlet on each side of a rectangular return air inlet  114 . Accordingly, in this aspect, the diffuser assembly  100  provides a four way supply air diffuser surrounding a center return air diffuser. 
     In an aspect, for example, the diffuser assembly  100  may be used with a T-bar ceiling or a plaster ceiling. For example, in an aspect, one or more fasteners  120  may be used to secure the diffuser assembly  100  to a T-bar or plaster ceiling. 
     In an aspect, for example, the diffuser assembly  100  may further include a collar  122  attachable to the supply air inlet  112  to facilitate attachment of a supply air duct (not shown) to the diffuser assembly  100 . 
     In an aspect, the first wall  104  and the cover member  108  extend in substantially parallel planes and the return air inlet  114  is aligned with the return air outlet  110  such that the internal return air duct  118  defines an unobstructed and substantially straight return air path  115  ( FIG. 5 ) between the return air inlet  114  and the return air outlet  110 . 
     In an aspect, the second wall  106  is positioned substantially perpendicular to the cover body of the cover member  108  such that the supply air path  117  ( FIG. 5 ) has a first direction at the supply air inlet  112  that is substantially perpendicular to a second direction at the supply air outlet  116 . In an aspect, the supply air path  117  ( FIG. 5 ) is unobstructed within the supply air chamber  105 . 
     In an aspect, the internal return air duct  118  is concentrically positioned within the housing  102 . In an aspect, for example, the internal return air duct  118  may have a circular cross-section along a plane orthogonal to the return air path  115  ( FIG. 5 ) defined by the internal return air duct  118 . In this case, the return air outlet  110  may also be circular. Alternatively, for example, in an aspect, the internal return air duct  118  may have a rectangular or square cross-section along a plane orthogonal to the return air path  115  ( FIG. 5 ) defined by the internal return air duct  118 . In this case, the return air outlet  110  may also be rectangular or square. 
     In an aspect, the housing  102  and/or the internal return air duct  118  may be manufactured using sheet metal, fiberglass, or any other similar material. 
     As such, the present aspects provide an efficient and compact concentric diffuser assembly providing supply and return air in a single unit. 
     As compared to conventional concentric diffusers, the concentric diffusers according to the present aspects provide improved airflow pattern since the supply and return air flows are unobstructed and the return air flow path is substantially straight. Therefore, the concentric diffusers according to the present aspects have a smaller overall size for the same airflow performance and pressure drop as conventional concentric diffusers. 
     Referring to  FIGS. 9 and 10 , in one non-limiting example aspect, an HVAC system  200  includes an air handling unit  202  ( FIG. 9 ) that controls an ambient condition of a room  204  via fluid communication with a diffuser assembly  100  installed on a ceiling  206  of the room  204 . The air handling unit  202  ( FIG. 9 ) may include various components that facilitate HVAC functionality, such as an air conditioning (A/C) unit, a furnace, a blower, a humidifier, a dehumidifier, a heat pump, or any other components for adjusting an ambient condition of the room  204 . The air handling unit  202  is coupled with the diffuser assembly  100  via a supply air duct  210  that provides supply air to the room  204  via the diffuser assembly  100 , and a return air duct  208  that returns air from the room  204  via the diffuser assembly  100 . 
     As compared to conventional diffusers, the diffusers according to the present aspects provide improved airflow pattern since the supply and return air flows are unobstructed and the return air flow path is substantially straight. Therefore, the diffusers according to the present aspects have a smaller overall size for the same airflow performance and pressure drop as conventional diffusers. 
     Further, as compared to conventional diffusers with a molded core, the diffusers according to the present aspects have a smaller overall size for the same airflow performance and pressure drop. As such, the diffusers according to the present aspects require less material, parts, and unit packing space for the same airflow performance and pressure drop as conventional diffusers with a molded core. For example, in an aspect, as compared to conventional diffusers with a molded core, the diffusers according to the present aspects may require 15-20% less material due to unit size reduction. Further, as compared to conventional diffusers with a molded core, the diffusers according to the present aspects require less assembly time. 
     Additionally, as compared to conventional diffusers with a molded core, the diffusers according to the present aspects may be manufactured with sheet metal and/or fiberglass duct board, thus requiring less process time. For example, in an aspect, as compared to conventional diffusers with a molded core, the manufacturing and assembly time may be reduced by 30% for the diffusers according to the present aspects. Further, the diffusers according to the present aspects do not require the molded core tooling. 
     As disclosed, the present aspects provide a diffuser assembly including a housing that defines an internal chamber having an open end, a return air outlet, and a supply air inlet; a cover sized to cover the open end, wherein the cover defines a return air inlet and a supply air outlet; and an internal return air duct longitudinally extending within the internal chamber and connecting the return air inlet and the return air outlet, wherein the internal return air duct includes an inner duct surface that defines a return air chamber within the internal return air duct and an outer duct surface that defines a supply air chamber between the housing and the outer duct surface, wherein the supply air chamber defines a supply air path between the supply air inlet and the supply air outlet. 
     Optionally, the housing includes a closed end opposite the open end, wherein the closed end and the cover extend in substantially parallel planes, and wherein the return air inlet is aligned with the return air outlet such that the internal return air duct defines an unobstructed and substantially straight return air path between the return air inlet and the return air outlet. 
     Optionally, the housing includes a first wall connected to a set of one or more adjacent walls to define the internal chamber, wherein the first wall includes a first internal surface that defines the return air outlet, wherein the set of one or more adjacent walls includes a second internal surface that defines the supply air inlet; and the cover includes a first internal grill wall and a second internal grill wall, wherein the first internal grill wall defines the return air inlet, and wherein the second internal grill wall defines the supply air outlet 
     Optionally, the first wall and the cover extend in substantially parallel planes. 
     Optionally, the set of one or more adjacent walls are positioned substantially perpendicular to the cover such that the supply air path has a first direction at the supply air inlet that is substantially perpendicular to a second direction at the supply air outlet. 
     Optionally, the supply air path is unobstructed within the supply air chamber. 
     Optionally, the internal return air duct is concentrically positioned within the housing. 
     Optionally, the internal return air duct has a circular cross-section along a plane orthogonal to a return air path defined by the internal return air duct. 
     Optionally, the return air outlet is circular. 
     Optionally, the internal return air duct has a rectangular or square cross-section along a plane orthogonal to a return air path defined by the internal return air duct. 
     Optionally, the return air outlet is rectangular or square. 
     Optionally, at least one of the housing or the internal return air duct comprises a sheet metal material. 
     Optionally, at least one of the housing or the internal return air duct comprises a fiberglass material. 
     In another aspect, a heating, ventilation, and air conditioning (HVAC) system is provided that includes an air handling unit and a diffuser assembly connected to the air handling unit via a supply air duct and a return air duct. The diffuser assembly includes a housing that defines an internal chamber having an open end, a return air outlet, and a supply air inlet; a cover sized to cover the open end, wherein the cover defines a return air inlet and a supply air outlet; and an internal return air duct longitudinally extending within the internal chamber and connecting the return air inlet and the return air outlet, wherein the internal return air duct includes an inner duct surface that defines a return air chamber within the internal return air duct and an outer duct surface that defines a supply air chamber between the housing and the outer duct surface, wherein the supply air chamber defines a supply air path between the supply air inlet and the supply air outlet. 
     In a further aspect, a diffuser assembly kit is provided that includes a housing that defines an internal chamber having an open end, a return air outlet, and a supply air inlet; a cover sized and engageable to cover the open end, wherein the cover defines a return air inlet and a supply air outlet; and an internal return air duct longitudinally extendable within the internal chamber and connectable to the return air inlet and the return air outlet, wherein the internal return air duct includes an inner duct surface that is positionable to define a return air chamber within the internal return air duct and an outer duct surface that is positionable to define a supply air chamber between the housing and the outer duct surface, wherein the supply air chamber defines a supply air path between the supply air inlet and the supply air outlet. 
     The previous description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to these aspects will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other aspects. Thus, the claims are not intended to be limited to the aspects shown herein, but is to be accorded the full scope consistent with the language claims, wherein reference to an element in the singular is not intended to mean “one and only one” unless specifically so stated, but rather “one or more.” The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any aspect described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects. Unless specifically stated otherwise, the term “some” refers to one or more. Combinations such as “at least one of A, B, or C,” “one or more of A, B, or C,” “at least one of A, B, and C,” “one or more of A, B, and C,” and “A, B, C, or any combination thereof” include any combination of A, B, and/or C, and may include multiples of A, multiples of B, or multiples of C. Specifically, combinations such as “at least one of A, B, or C,” “one or more of A, B, or C,” “at least one of A, B, and C,” “one or more of A, B, and C,” and “A, B, C, or any combination thereof” may be A only, B only, C only, A and B, A and C, B and C, or A and B and C, where any such combinations may contain one or more member or members of A, B, or C. All structural and functional equivalents to the elements of the various aspects described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. The words “module,” “mechanism,” “element,” “device,” and the like may not be a substitute for the word “means.” As such, no claim element is to be construed as a means plus function unless the element is expressly recited using the phrase “means for.”