Air Register with Flexible Vanes

Abstract

The present disclosure discloses an air register comprising an air vent housing that includes a first airflow redirector assembly to adjust airflow along the first axis and a second airflow redirector assembly to adjust airflow in the second axis. The air vent housing comprises a first housing component, a second housing component, and a collar that collectively define a cavity in which the first and second airflow redirectors are positioned to redirect air from an inlet to an outlet. The air register allows for control of airflow in one or more directions, while simplifying assembly of the air vent housing.

Description

BACKGROUND

Air registers are used in various applications to direct and control airflow from an air source (e.g., a blower) to a desired volume where heating or cooling is desired (e.g., a room, cabin, device, etc.). Effective control of airflow direction is essential for comfort and efficiency in automotive and heating, ventilation, and air conditioning (HVAC) systems.

Conventional air registers use rigid vanes to adjust airflow in different directions. Rigid vanes are typically pivotally mounted at one end and manipulated by its free end using, for example, an actuator and rigid link. That is, conventional air registers with rigid vanes linked by a rigid link features interconnected slats that pivot simultaneously when the link is moved by, for example, an actuator or otherwise. This coordinated movement adjusts the direction of the airflow, allowing control of air distribution within a volume.

Conventional air registers typically use pivoting vertical vanes typically with a connecting link bar to sync movement of the vanes, where rotation of the vertical vanes is typically provided by a slider knob and fork assembly that moves along a horizontal vane. Such conventional air registers typically entail numerous components that are mechanically coupled to control airflow, which increases complexity during manufacturer, part count, and moving parts that can seize or wear over time.

Therefore, there is a need for an improved air register that provides dual-directional airflow control with a simplified assembly process with enhanced functionality and durability.

SUMMARY

The present disclosure relates generally to an air register, substantially as illustrated by and described in connection with at least one of the figures, as set forth more completely in the claims. In an example, the present disclosure relates generally to an air register with flexible vanes.

DRAWINGS

The foregoing and other objects, features, and advantages of the devices, systems, and methods described herein will be apparent from the following description of particular examples thereof, as illustrated in the accompanying figures, where like or similar reference numbers refer to like or similar structures. The figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the devices, systems, and methods described herein.

FIGS. 1a and 1b illustrate, respectively, front and rear perspective views of an example air register in accordance with an aspect of the subject disclosure.

FIGS. 1c and 1d illustrate, respectively, first and second side elevation views of the example air register.

FIGS. 1e and 1f illustrate, respectively, top and bottom plan views of the example air register.

FIGS. 1g and 1h illustrate, respectively, front and rear elevation views of the example air register.

FIG. 1i illustrates a front perspective, cross-sectional view of the example air register taken along cut-line A-A (FIG. 1e).

FIGS. 2a through 2c illustrate, respectively, top plan views of Detail A (FIG. 1e) in a fully assembled configuration, a first partially assembled configuration with the first housing component removed, and a second partially assembled configuration with the first flexible air guide removed.

FIGS. 3a through 3c illustrate, respectively, top plan air flow diagrams of the air register taken along cut-line B-B (FIG. 1f) with its first airflow redirector assembly in a neutral position, a first extreme position, and a second extreme position.

FIGS. 3d and 3e illustrate, respectively, top plan views of Detail B (FIG. 3a) and Detail C (FIG. 3b).

FIG. 3f illustrates a front elevation view of the example air register with the first airflow redirector assembly in a neutral position.

FIG. 3g illustrates a front elevation view of the example air register taken along cut-line B-B (FIG. 1f) with the first airflow redirector assembly in a neutral position.

FIGS. 4a through 4c illustrate, respectively, side elevation air flow diagrams of the air register with its second airflow redirector assembly in a neutral position, a first extreme position, and a second extreme position.

DETAILED DESCRIPTION

References to items in the singular should be understood to include items in the plural, and vice versa, unless explicitly stated otherwise or clear from the text. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of conjoined clauses, sentences, words, and the like, unless otherwise stated or clear from the context. Recitation of ranges of values herein are not intended to be limiting, referring instead individually to any and all values falling within and/or including the range, unless otherwise indicated herein, and each separate value within such a range is incorporated into the specification as if it were individually recited herein. In the following description, it is understood that terms such as “first,” “second,” “top,” “bottom,” “side,” “front,” “back,” “upper,” “lower,” and the like are words of convenience and are not to be construed as limiting terms. For example, while in some examples a first side is located adjacent or near a second side, the terms “first side” and “second side” do not imply any specific order in which the sides are ordered.

The terms “about,” “approximately,” “substantially,” or the like, when accompanying a numerical value, are to be construed as indicating a deviation as would be appreciated by one of ordinary skill in the art to operate satisfactorily for an intended purpose. Ranges of values and/or numeric values are provided herein as examples only, and do not constitute a limitation on the scope of the disclosure. The use of any and all examples, or exemplary language (“e.g.,” “such as,” or the like) provided herein, is intended merely to better illuminate the disclosed examples and does not pose a limitation on the scope of the disclosure. The terms “e.g.,” and “for example” set off lists of one or more non-limiting examples, instances, or illustrations. No language in the specification should be construed as indicating any unclaimed element as essential to the practice of the disclosed examples.

The term “and/or” means any one or more of the items in the list joined by “and/or.” As an example, “x and/or y” means any element of the three-element set {(x), (y), (x, y)}. In other words, “x and/or y” means “one or both of x and y”. As another example, “x, y, and/or z” means any element of the seven-element set {(x), (y), (z), (x, y), (x, z), (y, z), (x, y, z)}. In other words, “x, y, and/or z” means “one or more of x, y, and z.”

The present disclosure relates to air registers, specifically to an air register with an air vent housing that incorporates or otherwise defines dual airflow redirectors (e.g., first and second airflow redirector assembly assemblies) to provide precise control of airflow through the air register along a first axis (e.g., a horizonal axis) and a second axis (e.g., a vertical axis). In some examples, the first axis and the second axis are orthogonal, but non-orthogonal configurations are also contemplated. The air register is particularly useful in automotive, HVAC systems, and other applications requiring meticulous control of air direction.

The disclosed air register offers a number of advantages. First, the disclosed air register enables precise control of airflow in both first and second axes. Second, the disclosed air register simplifies the assembly of the air vent housing. Third, the disclosed air register reduced the number of moving parts, thus reducing wear on the system over time. Fourth, the disclosed air register enhances user convenience and comfort through integrated dual-directional airflow control. Fifth, the disclosed air offers a robust and reliable air vent housing suitable for a variety of applications. Finally, the disclosed air register provides optimized flow path geometries to provide reduced system pressure and enhanced plume quality. For example, providing uniformity, minimized blooming/spreading, optimized airstream velocity at a prescribed distance from the air register, etc. One of skill in the art, however, will appreciate that this is a non-exhaustive list of advantages.

In one example, an air register comprises: an air vent housing that defines an inlet that is fluidically coupled to an outlet via a cavity; and an airflow redirector assembly positioned at the outlet and configured to adjust airflow from the cavity along an axis, wherein the airflow redirector assembly comprises a first frame, a second frame, and a plurality of flexible vanes that are coupled to each of the first frame and the second frame, wherein the second frame is configured to translate relative to the first frame along the axis, and wherein each of the plurality of flexible vanes is configured to flex when the second frame translates relative to the first frame.

In another example, an airflow redirector assembly for an air register comprises: a first frame; a second frame that is configured to translate relative to the first frame along an axis; and a plurality of flexible vanes, wherein each of the plurality of flexible vanes is coupled to the first frame and to the second frame, wherein the second frame is configured to translate relative to the first frame along the axis, and wherein each of the plurality of flexible vanes is configured to flex when the second frame translates relative to the first frame and configured to adjust airflow along the axis.

In yet another example, an air register comprises: an air vent housing that defines an inlet that is fluidically coupled to an outlet via a cavity; and an airflow redirector assembly positioned at the outlet and configured to adjust airflow from the cavity along an axis, wherein the airflow redirector assembly comprises a first frame, a second frame configured to translate relative to the first frame along the axis, and a plurality of flexible vanes that are coupled to each of the first frame and the second frame, wherein each of the plurality of flexible vanes is configured to flex when the second frame translates relative to the first frame, and wherein the first airflow redirector assembly is configured to rotate about relative to the air vent housing about an axis of rotation that is parallel to the axis.

In some examples, each of the plurality of flexible vanes includes a first end that is fixedly coupled to the first frame and a second end that is slidingly coupled to the second frame.

In some examples, the second end of each of the plurality of flexible vanes is sandwiched between a set of nibs formed in or on the second frame.

In some examples, the second frame is configured to translate relative to the first frame between a first extreme and a second extreme via a neutral position.

In some examples, the plurality of flexible vanes is configured to direct airflow in a first direction along the axis when the second frame is positioned at the first extreme.

In some examples, the plurality of flexible vanes is configured to direct airflow in a second direction along the axis that is opposite the first direction when the second frame is positioned at the second extreme.

In some examples, the plurality of flexible vanes is linear when the second frame is positioned at the neutral position.

In some examples, the plurality of flexible vanes is curved when the second frame is positioned at the first extreme or at the second extreme.

In some examples, the second frame is configured to translate relative to the first frame via a third frame that is fixedly coupled to said first frame.

In some examples, the third frame defines one or more channels configured to receive at least a part of the second frame.

In some examples, each of the plurality of flexible vanes is between 0.1 mm and 1.0 mm.

In some examples, each of the plurality of flexible vanes is about 0.25 mm.

In some examples, the air register further comprises a second airflow redirector assembly configured to adjust the airflow along a second axis that is transverse to said axis.

In some examples, the airflow redirector assembly is configured to rotate about relative to the air vent housing about an axis of rotation that is parallel to the axis.

The present disclosure provides an air register having an air vent housing with a first airflow redirector assembly to adjust airflow along a first axis (e.g., a horizonal axis) between a first direction and a second direction and a second airflow redirector assembly to adjust airflow along a second axis (e.g., a vertical axis) between a first direction and a second direction. The air vent housing, in an example, includes a first housing component (e.g., an upper housing), a second housing component (e.g., a lower housing), and an inlet frame that collectively join together to define a cavity in which the first and second airflow redirectors are positioned at least in part to guide air through the cavity from an inlet to an outlet. In some examples, the inlet frame joins and supports portions of the first and second housing components at the inlet (e.g., at the edge of the perimeter). The first and second housing components can be connected using a clip assembly with a first clip part integrated into the first housing component and a second clip part integrated into the second housing component.

FIGS. 1a and 1b illustrate, respectively, front and rear perspective views of an example air register 100 in accordance with an aspect of the subject disclosure. FIGS. 1c and 1d illustrate, respectively, first and second side elevation views of the example air register 100, while FIGS. 1e and 1f illustrate, respectively, top and bottom plan views of the example air register 100. FIGS. 1g and 1h illustrate, respectively, front and rear elevation views of the example air register 100, while FIG. 1i illustrates a front perspective, cross-sectional view of the example air register 100 taken along cut-line A-A (FIG. 1e).

The air register 100 is configured to control and adjust the direction of inlet airflow 110 entering via an inlet 106, through a cavity 114 of the air vent housing 102, and exiting via an outlet 108 as outlet airflow 112. In other words, the inlet 106 is fluidically coupled to the outlet 108 via the cavity 114. In the illustrated example, the air register 100 comprises a first housing component 102a (e.g., an upper housing, as illustrated), a second housing component 102b (e.g., a lower housing, as illustrated), and an inlet frame 102c. These components collectively define the cavity 114 through which air flows from the inlet 106 to the outlet 108.

The air register 100 further comprises a first airflow redirector assembly 118 to adjust airflow along a first axis (e.g., a horizonal axis) as indicated by arrow 116 between a first direction 116a (illustrated as left) and a second direction 116b (illustrated as right) and/or a second airflow redirector assembly 120 to adjust airflow along a second axis (e.g., a vertical axis) as indicated by arrow 122 between a first direction 122a (illustrated as up) and a second direction 122b (illustrated as down).

While the various figures illustrate an air register 100 that includes both a first airflow redirector assembly 118 and a second airflow redirector assembly 120, it is contemplated that an air register 100 could include only one of the first airflow redirector assembly 118 and the second airflow redirector assembly 120. For example, in some cases it may only be necessary or desired to provide directional control along one axis.

The first housing component 102a and second housing component 102b are configured to fit together, forming the primary structure of the air vent housing 102. The first housing component 102a can be joined with the second housing component 102b via one or more clip assemblies 104. The clip assembly 104 is used to join the first housing component 102a and second housing component 102b at one of a plurality of locations. In some examples, each of the one or more clip assemblies 104 includes a first clip part 104a and a second clip part 104b that are configured to secure to one another in a releasable manner.

As illustrated, the first housing component 102a can include or otherwise define the first clip part 104a of a clip assembly 104, while the second housing component 102b can include or otherwise define the second clip part 104b of the clip assembly. For example, the first clip part 104a can be integrated with the first housing component 102a, and the second clip part 104b can be integrated with the second housing component 102b. When the first and second housing components 102a, 102b are brought together, the clip parts 104a, 104b engage, securely holding the first and second housing components 102a, 102b together, thus simplifying the construction and maintenance of the air vent housing 102.

The inlet frame 102c is configured to join and support the first and second housing components 102a, 102b at or adjacent to the inlet 106 (e.g., by lining a portion of the interior surface as illustrated, or surrounding a portion of the exterior surface). The inlet frame 102c aids in aligning the first and second housing components 102a, 102b and provides additional structural support to the air vent housing 102 at the inlet 106. While the first and second housing components 102a, 102b are illustrated as separate components, a single, integrated housing component can instead be used to provide or define the structure(s) associated with the first and second housing components 102a, 102b.

As illustrated, each of the first housing component 102a and second housing component 102b are shaped to define a side profile that is generally curved. In some examples, the shape of the side profile can be selected to minimize turbulence as air flows through the cavity 114 from the inlet 106 to the outlet 108. In other examples, the shape of the side profile can be selected to accommodate the shape of internal components. In the illustrated examples, the shape of the side profile compliments (e.g., generally corresponds, shaped to avoid obstruction with, etc.) the shape of one or more components of the second airflow redirector assembly 120, such as its first flexible air guide 132a and the second flexible air guide 132b. For example, each of the first housing component 102a and second housing component 102b can be shaped to guide and/or shape the first flexible air guide 132a and second flexible air guide 132b. While the various figures illustrate the shape of the side profiles as being curved, it is contemplated that the shape of the side profile could be flat, ramped, triangular, rectangle, etc.

The first airflow redirector assembly 118 is positioned at the outlet 108 and at least partially within the cavity 114 to adjust the airflow along the first axis. This first airflow redirector assembly 118 comprises a rear static frame 124 (e.g., a first frame), a translating frame 126 (e.g., a second frame), and a plurality of flexible vanes 128 positioned between the rear static frame 124 and the translating frame 126.

FIGS. 2a through 2c illustrate, respectively, top plan views of Detail A (FIG. 1e) in a fully assembled configuration, a first partially assembled configuration with the first housing component 102a removed, and a second partially assembled configuration with the first flexible air guide 132a removed to better illustrate the plurality of flexible vanes 128.

As illustrated, the first airflow redirector assembly 118 can further comprise a front static frame 142 (e.g., a third frame) at its leading end (e.g., adjacent the outlet 108) to support, to increase rigidity, and to minimize gaps between the first airflow redirector assembly 118 and the air vent housing 102 as the first airflow redirector assembly 118 pivots about an axis of rotation 138.

The front static frame 142 can be designed as generally quadrilateral rigid component, depicted as rectangular, comprising a first rail 142a (illustrated as a top rail) joined to a second rail 142b (illustrated as a bottom rail) via a third rail and forth rail (illustrated as a pair of vertical rails) to define a rectangular opening through which air can flow.

The front static frame 142 can further define one or more channels 144 (e.g., a groove or slot) configured to slidingly support and engage the translating frame 126 via, for example, a ridge, lip, or other protrusion formed on the translating frame 126. In the illustrated example, a channel 144 can be formed lengthwise on a leading edge of the front static frame 142 and/or an interior surface (inward facing surface) of the first rail 142a and/or the second rail 142b. The translating frame 126 can be slidingly supported in, by, and/or between the channels 144.

The front static frame 142 and the rear static frame 124, in effect, define the static structure or frame while the translating frame 126, being supported by the front static frame 142, slides relative to the front static frame 142 and the rear static frame 124 to thereby flex and adjust the curve of the plurality of flexible vanes 128 (and thus the airflow direction).

Each of the plurality of flexible vanes 128 can be formed as a generally quadrilateral sheet of flexible material, illustrated herein as a rectangle. Similarly, both the rear static frame 124 and the translating frame 126 are designed as generally quadrilateral rigid components, also depicted as rectangles, comprising four rails (or links) that define a rectangular opening through which air can flow. While the example illustrates each of the flexible vanes 128, the rear static frame 124, and the translating frame 126 as generally quadrilateral, other geometric shapes are feasible depending on the specific design requirements and the shape of the housing 102 and/or the outlet 108. Alternative shapes may include oval, trapezoidal, and other polygonal configurations. Additional design considerations involve tailoring the components of the first airflow redirector assembly 118 to achieve specific output airflow velocities, ensuring optimal performance and efficiency of the air vent system.

In one example, the rear static frame 124 is fixed (e.g., immovable along the first axis) relative to the front static frame 142 and/or the air vent housing 102, while the translating frame 126 is configured to move (e.g., slide) relative to the rear static frame 124. For example, the translating frame 126 is configured to move along the first axis as indicated by arrow 116 between a first extreme position in the first direction 116a (left) and a second extreme position in the second direction 116b (right), while the rear static frame 124 remains fixed relative to the first axis. In some examples, the rear static frame 124 and the front static frame 142 are fixedly coupled to one another. In this example, the translating frame 126 can be configured to slide in and along the channel 144 along the first axis as indicated by arrow 116 between a first extreme position in the first direction 116a and a second extreme position in the first direction 116b.

The translating frame 126 can be adjusted relative to the rear static frame 124 and the front static frame 142 directly or via a mechanical linkage, which, in turn, can be connected to an external actuator. The external actuator can use a manual device, such as a slide tab, or an automated device (e.g., an electric motor, electric actuator, etc.). The rear static frame 124 and front static frame 142 remains fixed relative to the first axis, however, as will be appreciated, the first airflow redirector assembly 118 can be configured to pivot relative to the air vent housing 102 via the second airflow redirector assembly 120.

Each of the plurality of flexible vanes 128 is coupled at a first end 128a thereof to the rear static frame 124 and coupled at a second end 128b thereof to the translating frame 126. In some examples, one of the first end 128a and the second end 128b is fixedly coupled to one of the rear static frame 124 or the translating frame 126, while the other of the first end 128a and the second end 128b is slidingly coupled to the other one of the rear static frame 124 or the translating frame 126.

The first end 128a or the second end 128b can be fixedly coupled to one of the rear static frame 124 or the translating frame 126 via, for example, a friction fit, an interference fit, adhesive, fasteners, or the like. For example, the first end 128a or the second end 128b can be wedged into a slot formed in one of the rear static frame 124 or the translating frame 126. As best illustrated in FIGS. 3d through 3g, for example, each of the plurality of flexible vanes 128 is fixedly coupled to the rear static frame 124 at the first end 128a and slidingly coupled to the translating frame 126 at the second end 128b. In some examples, the plurality of flexible vanes 128 can be further supported to the fixed frame 124 via an intermediate frame that remains fixedly attached to the rear static frame 124.

Coupling an end of the flexible vane 128 slidingly allows for the flexible vane 128 to flex and bend without binding to maintain a smooth curve. That is, binding is more likely to occur when each of the first and second ends 128a, 128b is fixedly attached. To maintain alignment (i.e., in the second axis-illustrated as vertical), while enabling the plurality of flexible vanes 128 to slide relative to the translating frame 126, each of the plurality of flexible vanes 128 can be loosely sandwiched between a pair of protruding nibs 130, which are illustrated as generally cylindrical protrusion on each of the top and bottom sides (e.g., rails) of the translating frame 126. Therefore, in operation, the flexible vanes 128 can slip relative to the translating frame 126 to account for changes in arc shapes and arc lengths of the flexible vane 128 as they bend. While the pair of protruding nibs 130 are illustrated as generally cylindrical, other shapes are contemplated, including non-cylindrical and non-circular shapes.

Each of the plurality of flexible vanes 128 is therefore configured to flex between a first extreme curvature in the first direction 116a and a second extreme curvature in the second direction 116b via a neutral shape (e.g., where the flexible vanes 128 are in a default, linear or flat shape) as the translating frame 126 moves between the first extreme position and the second extreme position. While the second ends 128b of the plurality of flexible vanes 128 is illustrated as being aligned relative to one another, the plurality of flexible vanes 128 can be inwardly or outwardly aligned to each other (e.g., enabling a non-linear moving direction for aiming airflow in the first direction 116a (left) and/or the second direction 116b (right)).

FIGS. 3a through 3c illustrate, respectively, top plan air flow diagrams of the air register 100 taken along cut-line B-B (FIG. 1f) in a neutral position, a first extreme position in the first direction 116a, and a second extreme position in the second direction 116b. FIGS. 3d and 3e illustrate, respectively, top plan views of Detail B (FIG. 3a) and Detail C (FIG. 3b), while FIGS. 3f and 3g illustrate, respectively, front elevation views of the example air register 100 showing Detail E (FIG. 3f) and taken along cut-line B-B (FIG. 1f) in a neutral position.

The second airflow redirector assembly 120 generally comprises the first flexible air guide 132a, the second flexible air guide 132b, and one or more pivot connectors 134 (e.g., barrel connectors or other pivot joints and/or linkages) that allows for a rotational (or pivoting) movement. The second airflow redirector assembly 120 is positioned at least partially within the cavity 114 to adjust the airflow along the second axis. In an example, each of the pivot connectors 134 can includes a central pivot axle and pivot recess. In some examples, the pivot connectors 134 can include a pivot drive element (e.g., a gear-a wheel with teeth about its circumference) configured to engage a motor or lever via a worm gears, whether directly or via a drive train.

FIGS. 4a through 4c illustrate, respectively, side elevation air flow diagrams of the air register 100 with its second airflow redirector assembly 120 in a neutral position, a first extreme position in the first direction 122a, and a second extreme position in the second direction 122b.

The first flexible air guide 132a and the second flexible air guide 132b are positioned in the cavity 114 and effectively bridge the distance or span between the inlet 106 and the outlet 108 to effectively guide airflow therethrough. In the illustrated example, each of the first flexible air guide 132a and the second flexible air guide 132b are fixedly coupled to the first airflow redirector assembly 118 at a first end thereof. For example, the first flexible air guide 132a and the second flexible air guide 132b can be fixedly coupled to the front static frame 142.

The second end of each of the first flexible air guide 132a and the second flexible air guide 132b are, in contrast, slidingly coupled to the inlet frame 102c via a first slot 136a and a second slot 136b to allow each of the first flexible air guide 132a and the second flexible air guide 132b to slide or translate relative to the inlet frame 102c in the direction indicated by arrow 140.

Coupling an end of each of the first flexible air guide 132a and the second flexible air guide 132b slidingly allows for the first flexible air guide 132a and the second flexible air guide 132b to flex and bend without binding, which is more likely to occur when each end is fixedly attached. Therefore, in operation, the first flexible air guide 132a and the second flexible air guide 132b can slip relative to the inlet frame 102c to account for changes in arc shapes and arc lengths of the first flexible air guide 132a and the second flexible air guide 132b as they bend. In other words, the rotation coupled with slideable engagement at the first slot 136a and the second slot 136b allows the first flexible air guide 132a and the second flexible air guide 132b to bend naturally, optimizing the airflow to the first airflow redirector assembly 118.

In operation, inlet airflow 110 enters the air vent housing 102 through the inlet 106 and is directed through the cavity 114 towards the outlet 108 as outlet airflow 112. The first airflow redirector assembly 118 adjusts the first axis of the airflow as the vanes 128 are flexed (e.g., bent or curved), whereas the second airflow redirector assembly 120 adjusts airflow along a second axis by pivoting the first airflow redirector assembly 118 about an axis of rotation 138. Together, the first airflow redirector assembly 118 and the second airflow redirector assembly 120 provide precise control over the direction of the airflow, enhancing user comfort and system efficiency.

With reference to FIGS. 4b and 4c, the shape of the side profiles for the first housing component 102a and second housing component 102b can be selected to accommodate the shape of and compliment the shape of the first flexible air guide 132a and the second flexible air guide 132b as the second airflow redirector assembly 120 alternates between the first extreme position in the first direction 122a and the second extreme position in the second direction 122b. Specifically, with reference to FIG. 4b, when the second airflow redirector assembly 120 is positioned in the first extreme position in the first direction 122a, the first flexible air guide 132a generally follows or tracks, but is not compromised by, the first housing component 102a. Similarly, with reference to FIG. 4c, when the second airflow redirector assembly 120 is positioned in the second extreme position in the second direction 122b, the second flexible air guide 132b generally follows or tracks, but is not compromised by, the second housing component 102b.

One or more components of the air register 100 can be made from for example, synthetic or semi-synthetic polymers (e.g., plastics, such as acrylonitrile butadiene styrene (ABS) and polyvinyl chloride (PVC), etc.), composite materials (e.g., fiber glass), metal (or a metal alloy), or a combination thereof. Certain components of the air register 100 (e.g., air vent housing 102, rear static frame 124, translating frame 126, front static frame 144, etc.) may be fabricated as rigid components, while other components of the air register 100 (e.g., the flexible vanes 128, the first flexible air guide 132a, and the second flexible air guide 132b) may be fabricated as flexible components. The flexible components are fabricated using a material that is flexible and/or softer relative to the material of the rigid components.

The rigid components would typically be made from a durable plastic material, although other materials such as metal or composites can also be used. In some examples, the rigid components can be fabricated using a relatively hard plastic via a plastic injection molding process. In contrast, the flexible components can be formed (e.g., cut, stamped, etc.) from sheets of material (e.g., a thin sheet of material). Alternatively, one or more components of the air register 100 may be fabricated using material extrusion techniques, such as fused deposition modeling (FDM), stereolithography (SLA), selective laser sintering (SLS), material jetting, binder jetting, powder bed fusion, directed energy deposition, VAT photopolymerization, and other suitable types of additive manufacturing or 3D printing processes.

In fabricating the flexible components, suitable materials include silicone, valued for its high flexibility and temperature resistance; thermoplastic elastomers (TPE), known for their elasticity and resilience; and flexible polymers such as polyethylene (PE), polyvinyl chloride (PVC), thermoplastic polyurethane (TPU), and polypropylene (PP), which offer a balance of flexibility, strength, and cost-effectiveness. It is also conceivable that the flexible components could comprise a closed pore, foamed material and/or rubber flexible materials.

The material thickness must be optimized to maintain flexibility while ensuring structural integrity. For example, a material with a low elastic modulus, indicating that the material is flexible and capable of significant elastic deformation, can be thicker than a material with a higher elastic modulus. In any case, the flexible components are generally thin and very flexible to allow them to flex and alternate between extreme positions. The flexible components can be fabricated using a sheet of material that is between 0.1 and 2 mm thick, between 0.2 and 1.5 mm thick, between 0.2 and 1.0 mm thick, between 0.2 and 1.5 mm thick, or about 0.25 mm thick. However, the thickness can be affected by the rigidity of the material. In one non-limiting example, the flexible components can be fabricated using PVC, PP, and/or TPU sheets having a thickness of about 0.25 mm.

Incorporating reinforcements or textured surfaces can enhance airflow control capabilities. The material must also exhibit resistance to environmental factors such as temperature fluctuations and humidity. Additionally, the flexible components should be lightweight for ease of manipulation and installation, and must be non-toxic to ensure safety in applications like HVAC systems.

While the present method and/or system has been described with reference to certain implementations, it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted without departing from the scope of the present method and/or system. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. For example, block and/or components of disclosed examples may be combined, divided, re-arranged, and/or otherwise modified. Therefore, the present method and/or system are not limited to the particular implementations disclosed. Instead, the present method and/or system will include all implementations falling within the scope of the appended claims, both literally and under the doctrine of equivalents.

Claims

1. An air register, comprising: an air vent housing that defines an inlet that is fluidically coupled to an outlet via a cavity; andan airflow redirector assembly positioned at the outlet and configured to adjust airflow from the cavity along an axis, wherein the airflow redirector assembly comprises a first frame, a second frame, and a plurality of flexible vanes that are coupled to each of the first frame and the second frame,wherein the second frame is configured to translate relative to the first frame along the axis, andwherein each of the plurality of flexible vanes is configured to flex when the second frame translates relative to the first frame.

2. The air register of claim 1, wherein each of the plurality of flexible vanes includes a first end that is fixedly coupled to the first frame and a second end that is slidingly coupled to the second frame.

3. The air register of claim 2, wherein the second end of each of the plurality of flexible vanes is sandwiched between a set of nibs formed in or on the second frame.

4. The air register of claim 1, wherein the second frame is configured to translate relative to the first frame between a first extreme and a second extreme via a neutral position.

5. The air register of claim 4, wherein the plurality of flexible vanes is configured to direct airflow in a first direction along the axis when the second frame is positioned at the first extreme.

6. The air register of claim 5, wherein the plurality of flexible vanes is configured to direct airflow in a second direction along the axis that is opposite the first direction when the second frame is positioned at the second extreme.

7. The air register of claim 4, wherein the plurality of flexible vanes is linear when the second frame is positioned at the neutral position.

8. The air register of claim 4, wherein the plurality of flexible vanes is curved when the second frame is positioned at the first extreme or at the second extreme.

9. The air register of claim 1, wherein the second frame is configured to translate relative to the first frame via a third frame that is fixedly coupled to said first frame.

10. The air register of claim 9, wherein the third frame defines one or more channels configured to receive at least a part of the second frame.

11. The air register of claim 1, wherein each of the plurality of flexible vanes is between 0.1 mm and 1.0 mm.

12. The air register of claim 11, wherein each of the plurality of flexible vanes is about 0.25 mm.

13. The air register of claim 1, further comprising a second airflow redirector assembly configured to adjust the airflow along a second axis that is transverse to said axis.

14. The air register of claim 1, wherein the airflow redirector assembly is configured to rotate about relative to the air vent housing about an axis of rotation that is parallel to the axis.

15. An airflow redirector assembly for an air register, the airflow redirector assembly comprising: a first frame;a second frame that is configured to translate relative to the first frame along an axis; anda plurality of flexible vanes, wherein each of the plurality of flexible vanes is coupled to the first frame and to the second frame, wherein the second frame is configured to translate relative to the first frame along the axis, andwherein each of the plurality of flexible vanes is configured to flex when the second frame translates relative to the first frame and configured to adjust airflow along the axis.

16. The airflow redirector of claim 15, wherein each of the plurality of flexible vanes includes a first end that is fixedly coupled to the first frame and a second end that is slidingly coupled to the second frame.

17. The airflow redirector of claim 16, wherein the second end of each of the plurality of flexible vanes is sandwiched between a set of nibs formed in or on the second frame.

18. An air register comprising: an air vent housing that defines an inlet that is fluidically coupled to an outlet via a cavity; andan airflow redirector assembly positioned at the outlet and configured to adjust airflow from the cavity along an axis, wherein the airflow redirector assembly comprises a first frame, a second frame configured to translate relative to the first frame along the axis, and a plurality of flexible vanes that are coupled to each of the first frame and the second frame,wherein each of the plurality of flexible vanes is configured to flex when the second frame translates relative to the first frame, andwherein the first airflow redirector assembly is configured to rotate about relative to the air vent housing about an axis of rotation that is parallel to the axis.

19. The air register of claim 18, wherein each of the plurality of flexible vanes includes a first end that is fixedly coupled to the first frame and a second end that is slidingly coupled to the second frame.

20. The air register of claim 19, wherein the second end of each of the plurality of flexible vanes is sandwiched between a set of nibs formed in or on the second frame.