Patent Publication Number: US-2016245535-A1

Title: Concealed controlled air vent system, method and apparatus

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This Application claims priority on U.S. Provisional Application No. 62/103,124, now pending, filed on Jan. 14, 2015, which is herein incorporated by reference. 
    
    
     FIELD 
     The subject matter of the present disclosure relates to a system, method and apparatus for controlling air flow in either a supply or return air vent within a residential or commercial building. 
     BACKGROUND 
     Many existing and future homes and small businesses have heating, ventilation and cooling (HVAC) systems that are based on one or more air blowers connected to supply air and return air ducts. The system is typically controlled through the use of zone type system whereby more or less conditioned air by volume is delivered through restricted static dampers and/or manually controlled vent covers. Dampers within the ductwork typically allow the system to balance the air at vents to compensate for more restrictive ducts and or longer ducts. The end of the duct is typically terminated with a vent cover or a register which in many cases has a mechanical means to restrict airflow. The use of static dampers and manually controlled covers or registers may be problematic as even though a system may be optimised for a given situation, seasonal differences along with modal differences such as heating versus cooling may require continual adjustment to the airflow. Automatic zone systems solve these issues and are capable of adapting the airflow in an optimal manner with respect to comfort. 
     Placing automatically controlled dampers in existing ductwork may not be economically viable due to building construction issues that leave the ductwork concealed as is the case with many basements that have been finished off with wall or ceiling panels. 
     A number of methods for zone control have been developed. Alles (U.S. Pat. No. 6,983,889 issued on Jan. 10, 2006) proposes the use of air bladders placed in ductwork to regulate the air flow to different zones and control the temperature. A solution proposed by Kath (U.S. Pat. No. 5,927,599 issued on Jul. 27, 1999) also requires a special control unit to be installed in the existing ductwork to regulate air flow. These types of installations, requiring access or modifications to the ducts, are expensive to retro-fit. 
     Brinkerhoff et al. (U.S. Pat. No. 6,692,349 issued on Feb. 17, 2004) and Carter (U.S. Pat. No. 8,142,265 issued on Mar. 27, 2012) describe different forms of electrically controlled motor driven vents that can be used to replace manually controlled mechanical vents. Fisher (U.S. Pat. No. 7,130,720 issued on Oct. 31, 2006), Zou et al. (U.S. Pat. No. 7,832,465 issued on Nov. 16, 2010) and Kates (U.S. Pat. No. 8,020,777 issued on Sep. 20, 2011) each describe different zone control systems in which motorized air vents are used to regulate the air flow to different zones, with each zone controlled by its own zone thermostat. When retrofitting a building, such systems do not require the existing ducts to be modified and use wireless links between the vents and zone thermostats to avoid the need to install additional wiring. 
     The new vents must be provided in different sizes to meet the market requirements where many standard and non-standard sizes have been adopted. This is problematic as the installer must first determine what sizes are required before the supplier can fulfill the requirement. 
     Another problem with replacing existing vent covers or registers is that the new automatic vent or register may not meet the aesthetic expectations when compared with the original vent cover. Likewise some homes have historically significant or very expensive registers custom made for unique decorative purposes. 
     It would thus be desirable to provide a controlled air vent system, which would at least partly address the disadvantages of the existing technologies. 
     SUMMARY 
     It would thus be desirable to be provided with a novel controlled air vent system. 
     The embodiments described herein provide in one aspect an HVAC diffuser adapted to various boot sizes, comprising a base unit, and at least a first extension module adapted to be mounted to the base unit for increasing a transversal dimension of the diffuser. 
     The embodiments described herein provide in another aspect a method of installing a diffuser to an HVAC boot, comprising:
         a) providing a base unit;   b) providing at least one extension module;   c) mounting the extension module to the base unit for varying a span thereof in accordance with a size of the boot; and   d) mounting the assembled base unit and extension module to the boot.       

    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a better understanding of the embodiments described herein and to show more clearly how they may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings which show at least one exemplary embodiment, and in which: 
         FIG. 1A  is an illustration shown in perspective of a vent assembly according to one of various exemplary embodiments; 
         FIG. 1B  is an exploded view of the vent assembly of  FIG. 1A  with a duct and a register; 
         FIG. 1C  is a fragmented view partly in cross section of the vent assembly, the duct and the register of  FIG. 1B , shown in an assembled position; 
         FIG. 2A  is an illustration shown in perspective of a crutch according to one of various exemplary embodiments; 
         FIG. 2B  is a fragmented view partly in cross section of the vent assembly with the crutch of  FIG. 2A  applied as a suspension arm; 
         FIG. 3A  is a perspective view of a base unit of the vent assembly according to one of various exemplary embodiments; 
         FIG. 3B  is a block diagram of a control module according to one of various exemplary embodiments; 
         FIGS. 4A and 4B  are respectively exploded and assembled perspective views of a length extension integrated with the base unit of  FIG. 3A  according to one of various exemplary embodiments; 
         FIGS. 5A to 5E  are various perspective views of a width extension integrated with the base unit of  FIG. 3A  according to one of various exemplary embodiments; and 
         FIGS. 6A and 6B  are perspective views of the length extension shown respectively in closed and open positions, according to one of various exemplary embodiments. 
     
    
    
     DESCRIPTION OF VARIOUS EMBODIMENTS 
     The system, method and apparatus disclosed herein provides means to mitigate some shortcomings of known devices by providing a single product that may be adjusted in all three dimensions, so that it works with various sizes of rectangular duct openings and allows for controlling airflow while still using the existing vent cover or floor register. 
     In one aspect, there is provided a single controlled vent assembly that can be adjusted in size to meet the needs of duct work openings of various sizes and shapes. To this end, the vent assembly provided by the invention comprises a base unit that may be extended using various modules, or extensions. The base unit and various extensions may be provided to the user separately (for instance in a kit form), to be put together for a particular duct size, or they may be provided pre-assembled, to be adopted to a particular duct size by removing extensions along the length or width of the assembly or both. This system, method and apparatus allows a single assembly to meet the needs of the market without prior knowledge of the specific duct vent size openings. Any width or length sections that are not required may be kept for future applications or disposed of. 
     in another aspect, there is provided a controlled vent assembly that may be concealed beneath or behind the existing register cover without modification to the ductwork or existing register cover. Placement of the controlled vent is flexible in that the concealed assembly may rest within the boot of the ductwork on its frame or on crutches provided with the assembly that may easily be removed. The crutches are provided with sufficient length and may simply be trimmed to meet the needs of the specific application. The crutches may also be re-orientated to become suspension arms for applications where the heel of the ductwork vent opening is too long. Additional connection points on both the base unit and extension modules allows the assembly to be affixed to the walls of the vent boot portion of the ductwork. 
     In a third aspect, the extensions comprise functional components that may integrate with the controlled vent assembly, thus providing an incremental function or capacity at the same time as they provide the dimensional adjustment to fit various ductwork. 
     Details will now be provided on various exemplary embodiments of the present system, method and apparatus. 
     Referring to  FIG. 1A , a vent assembly  100  comprises a base unit  101 , an optional width extension  102 , an optional length extension  103 , and four crutches  104 . In this embodiment, the vent assembly  100  may have assembly width W and length L, so that it may fit into ductwork boot  99  as shown in  FIGS. 1B and 1C , and control the air flow through a register  97 . 
     Each of the four crutches  104 , an embodiment of which is shown in  FIG. 2A , comprises two tracks  1042  that may slide into matching grooves  1011  of any corner of the base unit  101  (see  FIG. 3A ), or into matching grooves  1021  of the width extension  102  if installed, or matching grooves  1031  of the length extension  103  if installed, as shown respectively in  FIGS. 5A and 4A . When installed, the crutches  104  may slide along these grooves to allow the vent assembly  100  to adapt to ducts with boots at various depths. 
     The vent assembly  100  may rest directly within the boot  99 , or may be supported by the crutches  104 , which crutches may slide in either direction to match the depth of the boot  99 . Furthermore, if the boot of the duct is too long, the crutches  104  can act as suspension arms by hanging them using the protruding lips  1043  from the upper edge of the boot  99  immediately beneath the register  97 , as illustrated in  FIG. 2B . Each crutch  104 , as shown in  FIG. 2A , also comprises a plurality of teeth  1044  that engage with a matching tooth on the wall of the base unit  101 , or of the width extension  102  or of the length extension  103 , and restricts the sliding motion of the crutch  104  and smart diffuser, which helps to keep the diffuser in position as installed by the user. 
       FIG. 3A  shows an illustration of the base unit  101 , wherein the Base unit  101  comprises a main frame  1014 , housing a plurality of flaps  1012  and a control module  1013  that is adapted to actuate the flaps  1012 , opening and closing them in order to allow or restrict air flow. The base unit  101  further includes connection points  1015  which may be used to secure the vent assembly  100  to either the duct itself or the pre-existing vent cover or air register using mechanical fasteners. The same connection points may be found on all extensions as well for the same purpose. 
       FIG. 3B  shows a block diagram of the control module  1013  comprising a microprocessor  1013 - 7 , a Memory  1013 - 9 , a DC Power Manager Battery Bank  1013 - 12  and a Reset Switch  1013 - 14 , which may be used to control other components including a motor control  1013 - 11  to drive a servo motor (not illustrated) used for actuating the flaps  1012 . Furthermore, the control module  1013  comprises several sensors that may provide detection of harmful gases and measure various properties of the air flow sooner than they may detect or measure same if they were placed outside the ductwork. Such sensors may include a CO Sensor  1013 - 3  that may detect carbon monoxide, a temperature T Sensor  1013 - 4 , and a humidity H-Sensor  1013 - 5 . In addition, the control module  1013  herein comprises a Microphone  1013 - 6 , LEDs  1013 - 8 , a Speaker  1013 - 15 , and a Wireless Transceiver  1013 - 13  to communicate with a user device. Environmental sensors for temperature and humidity may provide local or remote feedback to enable control of the airflow to meet comfort requirements. The microphone may be used to provide local or remote control of the airflow to minimise undesirable noise generated by the airflow due to fractional angular control of the actuating flaps at various differing air velocities. 
     With reference to  FIG. 3A , in an embodiment, a width W and a length L′ of the base unit  101  are typically chosen to fit the smallest forced air duct boot that is available generally for home HVAC installations, and either dimension can be augmented independently or in combination in order to fit a range of duct sizes, that is by adding either width or length extensions, or both. Thus, as shown in  FIGS. 4A and 4B , a length extension  103  may be added to the base unit  101  to achieve the same length L of the assembly shown in  FIG. 1A , while maintaining the width W′. The length extension  103  comprises tracks  1032  that may slide into the grooves  1011  of the base unit  101 , but also includes grooves  1031  that allow the tracks  1042  of the crutches  104  to slide therein to provide the depth support for the vent assembly  100 , as mentioned hereinabove. 
     Likewise, as shown in  FIG. 5A , the width extension  102  may be added to the same base unit  101  to achieve, for example, an assembly having a width W and a length L. The width extension  102  comprises a flap  1023  that may be connected to the flaps  1012  of the base unit  101  via a bridge  12  shown in  FIG. 5B . The resulting flap assembly  10123 , shown separately in  FIG. 5C , may thus be installed in the vent assembly  100  and controlled by the servo motor of the control module  1013 , as shown in  FIG. 5D , thereby providing the same behaviour in the extension  102  as in the rest of the vent assembly  100 . 
     The width extension  102  comprises tracks  1022  that may slide into the grooves  1011  of the base unit  101 , and also includes grooves  1021  that allow the tracks  1042  of the crutches  104  to slide therein to provide the depth support for the vent assembly, thereby resulting in the complete vent assembly  100  shown in  FIG. 5E , which supports a different duct size than the one supported by the base unit  101  or by another vent assembly having a different extension. 
     The various width and length extensions may be designed in accordance with the present teachings in order to support any ductwork with rectangular registers. For example,  FIGS. 6A and 6B  show the length extension  103  that may be added to the vent assembly  100  of  FIG. 5E  in order to obtain the vent assembly  100  of  FIG. 1A . Furthermore, the length extension  103  of  FIGS. 6A and 6B  comprises a battery housing  1024 , with a connector  1025 , thereby allowing the length extension  103  to provide additional power to the vent assembly as well as providing support for a different duct size. Those of skill in the art may appreciate that the extension  103  may provide housing for devices other than batteries, with connector  1025  comprising data as well as power connectivity, for allowing the introduction of new functions not available in the control module  1013 . 
     According to the present system, the various embodiments and configurations of the vent assembly  100  may thus support various duct sizes using a combination of the base unit  101  and the two extensions  102  and  103 , in addition to the crutches  104 . These extensions  102  and  103  may further provide additional functions that integrate with the base unit  101  using power and data connectors. 
     it is noted that the vent assembly  100  may be DC or AC line powered, and that it can be wired back to a central controller or another unit for control and communication purposes. 
     With the present system, a great deal of flexibility of the vent assembly is offered to the consumer 
     Finally, while the above description provides examples of the embodiments, it will be appreciated that some features and/or functions of the described embodiments are susceptible to modification without departing from the spirit and principles of operation of the described embodiments. Accordingly, what has been described above has been intended to be illustrative of the embodiments and non-limiting, and it will be understood by persons skilled in the art that other variants and modifications may be made without departing from the scope of the embodiments as defined in the claims appended hereto.