Patent Publication Number: US-4545294-A

Title: Frictional blade assembly for grille

Description:
This invention relates to a frictional blade assembly for an air grille for use in association with air ventilation systems. 
     BACKGROUND OF THE INVENTION 
     Conventional air grilles generally comprise a rectangular metal frame and a number of parallel transverse blades rotatably mounted to the frame. The blades are generally secured by friction in a particular angular position with respect to the frame and to the flow of air. 
     Several embodiments of such typical grilles are disclosed in U.S. Pat. No. 4,103,601. However, conventional means for achieving a tight frictional fit between blade and the frame may suffer from one of two disadvantages. First, if the blade length is increased, for instance in the event that a wider air duct is used, the friction torques may be inadequate to resist the torque exerted on the blades by the pressure of the air moving in the duct. Consequently, the blade may be rotated away from the desired angular position. Second, a means for achieving an adequate frictional fit may be expensive to manufacture and install. For instance, the embodiments illustrated in FIGS. 1 to 3, 7, 8, and 15 to 23, of U.S. Pat. No. 4,103,601 all require costly cutting or stamping operations in their manufacture. In the case where a blade has been roll-formed from sheet metal into a generally hollow tubular shape, such cutting or stamping operations may be difficult, and thus even more expensive to complete. The manufacture of the grille assembly of some embodiments such as illustrated in FIG. 17, may require further operations. For example, the embodiment of FIG. 17 necessitates the bendng over of two tabs 38 to secure a blade in place. Any such additional installation operations further increase the cost of the assembly. 
     Similarly, the embodiment of FIG. 6 requires a metal support bar to be provided with plastic pins having frictional formations formed thereon. The formation of holes in the metal bar and the insertion of the pins into such holes are expensive operations. Also, the manufacture of frictional formations on the pins (as illustrated both in FIGS. 6 and 14) may require expensive dies. In order to achieve a satisfactory frictional fit, the tolerances for the dimensions of all (there are three illustrated) frictional formations must be carefully controlled. 
     The same frictional formations of FIGS. 6 and 14 may be subject to significant wear or deterioration when blades are fitted over the formations. Furthermore, the frictional formations increase the necessary blade thickness, thus reducing the free area of the grille through which air may flow. Alternatively, the diameter of the pins may be reduced to allow room for the frictional formations. However, the reduction in pin diameter may result in a loss of pin strength and durability. For these reasons, use of pins with frictional formations may not be desirable. 
     It is therefore desirable to provide a frictional blade assembly for an air grille in which the means for achieving a tight frictional fit is simple and inexpensive both to manufacture and to install. 
     BRIEF STATEMENT OF THE INVENTION 
     This invention is a frictional blade assembly for grilles to be used in association with air ventilation systems wherein said assembly comprises, a first thermoplastic support bar defining a stem, which stem defines a longitudinal axis, and having a plurality of coplanar abutments extending normal to one side of said axis, each of said abutments being more or less the same length and having an outer surface of uniform generally cylindrical shape and having more or less the same diameter, said abutments being formed integrally as part of said support bar, a plurality of blades, each of said blades defining a first end and a second end and being of uniform cross-sectional shape and size along its length, each said blade defining a generally streamline-shaped tube, said tube defining a first edge, a second edge and an internal space, said internal space at said first edge being of generally circular cross-section over an arc of approximately 270°, said circular cross-section having a diameter of between 0.002&#34; and 0.004&#34; less than that of said abutments, said first end of said blades being rotatably attached to respective said abutments by inserting a said abutment into said internal space at the first edge of a said blade, whereby a frictional fit between each said abutment and a respective said blade is obtained, and, a second thermoplastic support bar defining a stem, which stem defines a longitudinal axis, and having a plurality of coplanar abutments extending normal to one side of said axis, said second bar being affixed to said second ends of said blades at said first edges, whereby said blades may be rotated relative to said first and second bars against a frictional resistance. 
     It is an objective of the invention to provide means for achieving a frictional fit between the blades and the framework of an air grille and which is of reduced diameter to minimise blade thickness and maximise open area for air flow. 
     It is a further objective of the invention to provide for a frictional blade assembly that is inexpensive and simple to manufacture and install. 
     The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be had to the accompanying drawings and descriptive matter in which there are illustrated and described preferred embodiments of the invention. 
    
    
     IN THE DRAWINGS 
     FIG. 1 is a partially cut away perspective view of one embodiment of the invention as it may be used in a complete grille assembly; 
     FIG. 2 is a cross-section along the line 2--2 of FIG. 1; 
     FIG. 3 is an exploded view of a partial frictional blade assembly according to the invention; 
     FIG. 4 is a cross-section of one embodiment of an air deflector blade; 
     FIG. 5 is a close-up view, in perspective, of the insertion of a supporting abutment into an air deflector blade in one embodiment of the invention; 
     FIG. 6 is a cross-section along the line 6--6 of FIG. 1; 
     FIG. 7 is a cross-section along the line 7--7 of FIG. 6; 
     FIG. 8 is a cross-sectional view similar to that shown in FIG. 7 of an alternate embodiment; 
     FIG. 9 is a plan view of an alternate embodiment of the invention, and, 
     FIG. 10 is a cross-section along the line 9--9 of FIG. 9. 
    
    
     DESCRIPTION OF A SPECIFIC EMBODIMENT 
     Referring now to FIGS. 1 and 2, there is illustrated a typical grille assembly 10, comprising a rectangularly-shaped grille frame 12 within which is supported frictional blade assembly 14. Grille frame 12 may comprise typical frame members 16, such as are illustrated in FIGS. 1 to 5 of U.S. Pat. No. 4,103,601, held together at its corners in any conventional fashion. Frame members 16 may define a recess 18 within which blade assembly 14 may be supported. Such a recess 18 is preferably trapezoidal in cross-sectional shape, although other shapes may be acceptable. Blade assembly 14 includes a plurality of rotatable, transverse, parallel air deflector blades 15. The angular position of each such blade 15 in operation is fixed with respect to frame members 16. Such angular position may be altered manually or otherwise. The direction of flow of air is changed by blades 15 from the direction indicated by arrow A at the entrance to grille assembly 10 to the direction indicated by arrow B at the exit of grille assembly 10. The angle through which air is deflected is typically less than 20°. Deflection through a greater angle may result in blade vibration or air noise. 
     Referring to FIG. 3, frictional blade assembly 14 includes a first thermoplastic support bar 20. Support bar 20 defines a stem 20a which defines a longitudinal axis L. Support bar 20 further defines a plurality of coplanar abutments 20b, extending essentially normal to one side of axis L, and formed integrally with stem 20a. Each of abutments 20b defines an outer surface of uniform generally cylindrical shape (see FIGS. 6 and 7). Each of abutments 20b is of more or less the same length and diameter as all other abutments 20b. Each abutment 20b defines a tapered free end 20c. Free end 20c may conveniently be of frusto-conical shape but other shapes may be acceptable. Support bar 20 may further define longitudinal stem extensions 20d, which may be used to assist in positioning frictional blade assembly 14 within grille frame 12. Bar 20 may define a surface 20f at which abutments 20b join stem 20a. 
     In a further embodiment, an abutment 20b may define channel means 20e extending along the surface of abutment 20b (see FIG. 8). Such channel means 20e may offer advantages in the event that blades 15 or blade assembly 14 are cleaned, painted or otherwise treated. During operations of this nature, fluid may be trapped within blades 15. If the blade assembly 14 is later subjected to heat, such fluids may be vapourized and pressurized. The pressurization may cause damage to the blade assembly 14. The provision of channel means 20e allows fluid and vapour to escape the interior of blades 15 without causing any damage. 
     Stem 20a and extensions 20d may conveniently have a trapezoidal cross-section adapted to dovetail into recess 18 of frame member 16 (see FIG. 6). Other shapes adapted to fit within recess 18 may be acceptable. Stem 20a may have sufficient depth so that surface 20f is raised above recess 18. Such a configuration conveniently allows surface 20f to act as a bearing surface keeping the end of a blade 15 out of contact with frame members 16. Also, in the event that the blade assembly 14 is cleaned, painted or otherwise treated, fluid may escape without restriction by frame members 16. 
     A plurality of blades 15 are rotatably attached to first thermoplastic support bar 20. Each of blades 15 defines a first end and a second end and is of uniform cross-sectional shape and size along its length. Each blade 15 is formed to define a generally streamline-shaped tube. Each such blade may be generally planar in shape or may be curved, or may be of any shape that is generally known in the art. Each blade 15 defines a first edge 15a, a second edge 15b, and an internal space 22. The internal surface of first edge 15a defines a portion 22a of space 22, said portion 22a, being a generally circular cross-section over an arc of approximately 270°. Said circular cross-section may conveniently have a diameter of between 0.002&#34; and 0.004&#34; less than that of abutments 20b. A blade 15 may define at least one external surface groove 23a (see FIG. 4) along its length. Such external grooves 23a form internal ridges 23b. Such groove 23a and ridge 23b formations provide blade 15 with additional stiffness and strength. 
     Blades 15 are rotatably attached to abutments 20b by inserting abutments 20b into portion 22a of space 22 at a same one end of blades 15. The relative diameter of portion 22a and of abutment 20b and a 270° arc of portion 22a ensures that first edge 15a acts like a spring clamped around and radially pushing against abutment 20b. FIG. 5 illustrates a close up view of an end of blade 15 about to be fitted over abutment 20b. The figure in phantom indicates the position of blade 15 when abutment 20b is fully inserted into blade 15. The blades 15 are mounted and adjusted so that each blade 15 defines the desired angle with respect to stem 20a through which angle air is to be deflected. 
     The width of a blade 15, that is, the distance between the first edge 15a and the second edge 15b, corresponds approximately to the distance between abutments 20b. Such width may conveniently be within the range 0.490&#34; to 1.010&#34;. Conceivably, blades 15 may be rotated to a more or less vertical position to essentially close grille assembly 10 to the flow of air although this would be most unusual. In order that the frictional torque applied to blades 15 is sufficient to resist the torques generated by air pressure at this extreme position, the diameter of abutments 20b is preferably between 0.002&#34; and 0.004&#34; greater than that of portion 22a of space 20. If more extreme conditions must be met or if blades having a width greater than 1.0&#34; are used, additional frictional forces may be generated by decreasing the diameter of portion 22a or by increasing the diameter of abutments 20b. The width of blades 15 for use in association with abutments 20b of a particular diameter is limited by the fact that blades 15 must be able to maintain a sufficient spring-like clamping action against the abutments 20b. 
     The diameter of abutments 20b is limited both by the thickness of the material used in blades 15 and by the amount of free area required to allow air to flow through the grille 10. The maximum free area for air to flow through a grille 10 is available when blades 15 are oriented parallel to the flow of air entering the grille 10. With the blades 15 in such an angular position, air is not deflected by the blades 15 and there is no change in direction of air flow. When the blades 15 are angled with respect to frame 16, there is less area in the grille 10 available for the flow of air. It is possible that the flow of air may be restricted below a predetermined acceptable level. 
     If the diameter of abutments 20b is too great the blades will be too thick. In this case, even when blades 15 are parallel to the air flow, there may be an insufficient flow of air through grille 10 due to the thickness of the blades. Consequently, abutments 20b must have a small enough diameter to permit the use of thinner blades and thus allow a satisfactory air flow through grille 10 even at the desired angular orientation of blades 15. 
     The area available for the flow of air through the grille 10 is further reduced by the thickness of the material used to form blades 15. The thickness of such material must be sufficient to allow blades 15 to the conveniently manufactured and to satisfactorily clamp around abutments 20b. Consequently, the combination of abutment diameter and material thickness must define a total blade thickness that will allow a satisfactory air flow through grille 10 at the desired angular orientation of blades 15. 
     The diameters of abutments 20b and the blade material thickness are preferably related to the amount of area of the grille 10 by the following relationship: ##EQU1## 
     When a longer blade is used, more air pressure torque is applied to the blade. The longer an abutment 20b is, the more frictional torque can be generated. Thus, in order to counter the air pressure torque, longer abutments may be used. Preferably, blade lengths are less than or equal to 24&#34; and abutments 20b are less than or equal to 1.0&#34; in length exclusive of the length of frustoconical end 20c. 
     The second ends of blades 15 may be rotatably attached to a second thermoplastic support bar 24. Second support bar 24 may be essentially identical to first support bar 20. Second support bar 24 defines abutments 24b and stem extensions 24d. Abutments 24b are inserted into portion 22a of space 22 at the second end of each of blades 15. First edge 15a acts in a spring-like fashion against abutment 24b. 
     The blades 15 are thus supported between and by support bars 20 and 24. The friction between a blade 15 and its associated abutments 20b and 24b is sufficient to prevent blade 15 from rotating from its pre-determined desired angular position with respect to frame 16. Yet, such friction is not so great as to prevent such angular position from being manually, or otherwise, adjusted or changed, if desired. Nor is such friction so great as to interfere with the ease of assembly of the frictional blade assembly 14. 
     In operation, frictional blade assembly 14 is inserted into grille frame 12. This is accomplished by sliding support bar 20 and 24 into recesses 18 in frame members 16. The grille assembly is then installed in the desired air duct. The angular orientation of blades 15 to grille 10 may be manually adjusted to the desired position. The frictional blade assembly 14 will then operate to deflect the flow of air as directed. 
     Several factors contribute to the success of this invention. First, the materials of the invention and surface finishes of such materials may be selected and prepared to provide suitable frictional resistances to air pressure torques. Thermoplastic polyester (for the support bars 20 and 24) and roll-formed aluminum sheet metal (for the blades 15), both with smooth surface finishes, have a satisfactory coefficient of static friction relative to each other and have been found to be suitable materials to provide acceptable frictional resistance. Preferably, such thermoplastic polyester has between 20 and 30% glass fibre content for added durability and strength. Materials such as POCAN B #4225 or #4235 (trade mark) may be acceptable materials. POCAN B #4225 or #4235 has a coefficient of static friction relative to lapped steel plate of between 0.11 and 0.13. Aluminum has a coefficient of static friction relative to mild steel of between 0.5 and 0.7. Both thermoplastic polyester and aluminum are inexpensive, strong, tough, durable, corrosion-resistant, and light-weight, and thus the frictional blade assembly according to the invention has similar properties and is easy to assemble and install. Other blade materials such as sheet steel, plastic or nylon may be acceptable. 
     Second, the smooth cylindrical form of abutments 20b and 24b and the corresponding cylindrical form portion 22a of internal space 22 provides a maximum amount of surface area over which frictional forces may be developed. Third, the relative diameters of abutments 20b and 24b and of portion 22a of space 22 (the diameter of abutments 20b being preferably between 0.002&#34; and 0.004&#34; greater than that of portion 22a) are important to provide satisfactory frictional forces and yet maintain ease of assembly and long life. Fourth, the arc of circular portion 22a extending over about 270° is also important to allow first edge 15a of blade 15 to act in a spring-like fashion against abutments 20b and 24b. This provides satisfactory radial forces and corresponding frictional forces between the abutments and the internal surfaces of first edges 15a. Fifth, the relationship between the diameter of abutments 20b and the width of blades 15 is important to adjust the required frictional forces when different distances between abutments are used and to maintain a suitable grille maximum free area. Sixth, the relationship between abutment length and blade length may be used to adjust the required frictional forces when different blade lengths are used. Seventh, the relationship between abutment diameter to material thickness of blades 15 is important to adjust the strength of the spring-like action of blades 15 against abutments 20b and 24b. Eighth, the ratio of grille maximum free area to the total grille area is important to ensure a satisfactory flow of air through grille 10 when blades 15 are positioned at the desired angular orientation. 
     Referring to FIGS. 9 and 10, in a further embodiment, the angular position of blades 15 with respect to frame 12 may be permanently fixed. Such an embodiment may be conveniently used in a return air grille. 
     The first edge 15a of blades 15 are affixed, as in the embodiment described above and illustrated in FIGS. 1 to 8, to first and second thermoplastic support bars 20 and 24. In the embodiment of FIGS. 9 and 10, the second edge 15b of blades 15 is affixed to third and fourth thermoplastic support bars 26 and 28 respectively, which may conveniently be essentially identical to support bars 20 and 24. Bars 26 and 28 define stems, stem extensions, and abutments, similar to those of bars 20 and 24. 
     The internal surface of the second edge 15b of each blade 15 defines a portion 22b of internal space 22, said portion being of generally circular cross-section over an arc of about 270°. As in the case of the first edge 15a, said circular cross-section may conveniently have a diameter of between 0.002&#34; and 0.004&#34; less than that of the abutments of support bars 26 and 28. The abutments of bars 26 and 28 are inserted into portion 22b. Such a relationship between the diameters of portion 22b and the abutments of bars 26 and 28 ensures that the second edge 15b will not vibrate against the abutments and allows for the use of standard parts. All support bars 20, 24, 26 and 28 may conveniently be essentially identical. Thus, manufacturing costs are less than would be the case if the first edge support bars 20 and 24 were different from second edge support bars 26 and 28. However, bars 26 and 28 do not necessarily have to be identical in every respect to bars 20 and 24. It is sufficient if bars 26 and 28 have a shape similar to that of bars 20 and 24 and if bars 26 and 28 are dimensioned to be insertable into said portions 22b of internal space 22, whereby to prevent rotation of blades 15 about the abutments of bars 20 and 24. 
     Frame members 16 define a second recess 30 within which bars 26 and 28 may be supported. As in the case of recess 18, recess 30 is preferably trapezoidal in cross-sectional shape in order to dovetail with the stems of bars 26 and 28. 
     The abutments of bars 26 and 28 may be vertically offset from abutments 20b and 24b, respectively, in order to define the specific angle at which blades 15 are to be oriented. Stem extensions on bars 26 and 28 may have to be truncated or cut off, depending on the chosen blade angle. 
     In a further embodiment, it may be possible to utilize a second support bar 24, defining abutments which act only as pivots for blades 15. In such an embodiment, the first bar 20 is sufficient to retain blades 15 in the desired angular position. Second bar 24 does not assist in preventing rotation of blades 15. 
     All the above factors permit the manufacture of specific sizes and capacities of grilles to suit many requirements. Yet, the qualities of low cost, durability and simplicity of manufacture and installation are maintained. Thus, the frictional blade assemblies may be manufactured as and when ordered and required. Inventory may therefore be conveniently stored as stacking blades and frame members in standard lengths. The blades are economically formed from strip sheet aluminum by roll forming. Lengths of hollow roll formed blades are saw cut as desired to provide blades having straight-cut ends. The use of blades having straight ends in a blade assembly according to the invention avoids the difficult and costly cutting and notching operations on hollow roll-formed blade stock. Furthermore, cutting of blades and assembly of blade assemblies and grilles may be automated to reduce the amount of hand-labour. Such automated assembly procedures may increase the speed of manufacture, thus yielding a faster response to orders. 
     The foregoing is a description of a preferred embodiment of the invention which is given here by way of example only. The invention is not to be taken as limited to any of the specific features as described, but comprehends all such variations thereof as come within the scope of the appended claims.