Patent Application
20250027675
This application claims priority from and the benefit of India Provisional Patent Application No. 202321048660, entitled “A DIFFUSER WITH SELF-LOCKING BLADES,” filed Jul. 19, 2023, which is hereby incorporated by reference in its entirety for all purposes.
This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.
Heating, ventilation, and air conditioning (HVAC) systems are utilized in residential, commercial, and industrial environments to control environmental properties, such as temperature and humidity, for occupants of the respective environments. The HVAC system may regulate the environmental properties through delivery of a conditioned air flow to the environment. For example, the HVAC system generally includes an HVAC unit that is fluidly coupled to various rooms or spaces within the building via an air distribution system, such as a system of ductwork. The HVAC unit may be operable to direct a heated air flow or a cooled air flow through the ductwork and into the spaces to be conditioned. In this manner, the HVAC unit facilitates regulation of environmental parameters within the rooms or spaces of the building.
A temperature of the conditioned air supplied to the spaces may determine or affect a density of the conditioned air and, thus, a relative buoyancy of the conditioned air, with respect to ambient air within the space. Differentials in buoyancies of the heated or cooled air supplied to the space and the ambient air within the space may affect natural convective forces that induce air dispersion and/or air movement within the space. As such, the distribution of conditioned air within the space may vary based on an operational mode (e.g., heating mode, cooling mode) under which the HVAC unit operates and a discharge direction at which the conditioned air is directed into the space. Unfortunately, conventional HVAC systems may direct conditioned air into spaces of the building at fixed discharge directions, without regard to the temperature of the air being supplied to the spaces and/or the operational mode of the HVAC unit, which may impede effective air distribution across the spaces.
In one embodiment, a diffuser assembly for a heating, ventilating, and air conditioning (HVAC) system includes a frame having an inlet configured to receive an air flow and a blade assembly configured to couple to the frame. The blade assembly includes a support rail having a plurality of slots formed therein and a plurality of blades configured to couple to the support rail. Each blade of the plurality of blades is configured to extend within a respective slot of the plurality of slots.
In another embodiment, a diffuser assembly for a heating, ventilating, and air conditioning (HVAC) system includes a blade assembly configured to couple to a frame of the diffuser assembly, a support rail of the blade assembly, and a plurality of blades of the blade assembly. The support rail includes a plurality of slots formed therein, and each slot of the plurality of slots comprises a respective first geometry. Each blade of the plurality of blades includes a retention portion configured to extend within a corresponding slot of the plurality of slots, and the retention portion includes a respective second geometry corresponding to the respective first geometry of the corresponding slot of the plurality of slots.
In a further embodiment, a diffuser assembly includes a frame defining an air flow path configured to direct an air flow through the diffuser assembly, a support rail disposed within the air flow path, and a plurality of blades disposed within the air flow path. The support rail includes a plurality of slots formed therein, and each slot of the plurality of slots comprises a first geometry. The plurality of blades is coupled to the support rail, each blade of the plurality of blades includes a retention portion extending within a respective slot of the plurality of slots, the retention portion includes a second geometry corresponding to the first geometry, and the support rail is configured to retain each blade of the plurality of blades in a respective angular orientation relative to a direction of the air flow through the diffuser assembly.
One or more specific embodiments of the present disclosure will be described below. These described embodiments are only examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.
As used herein, the terms “approximately,” “generally,” and “substantially,” and so forth, are intended to convey that the property value being described may be within a relatively small range of the property value, as those of ordinary skill would understand. For example, when a property value is described as being “approximately” equal to (or, for example, “substantially similar” to) a given value, this is intended to mean that the property value may be within +/−5%, within +/−4%, within +/−3%, within +/−2%, within +/−1%, or even closer, of the given value. Similarly, when a given feature is described as being “substantially parallel” to another feature, “generally perpendicular” to another feature, and so forth, this is intended to mean that the given feature is within +/−5%, within +/−4%, within +/−3%, within +/−2%, within +/−1%, or even closer, to having the described nature, such as being parallel to another feature, being perpendicular to another feature, and so forth. Further, it should be understood that mathematical terms, such as “planar,” “slope,” “perpendicular,” “parallel,” and so forth are intended to encompass features of surfaces or elements as understood to one of ordinary skill in the relevant art, and should not be rigidly interpreted as might be understood in the mathematical arts. For example, a “planar” surface is intended to encompass a surface that is machined, molded, or otherwise formed to be substantially flat or smooth (within related tolerances) using techniques and tools available to one of ordinary skill in the art. Similarly, a surface having a “slope” is intended to encompass a surface that is machined, molded, or otherwise formed to be oriented at an angle (e.g., incline) with respect to a point of reference using techniques and tools available to one of ordinary skill in the art.
As briefly discussed above, a heating, ventilation, and/or air conditioning (HVAC) system may be used to thermally regulate a space within a building, home, or other suitable structure. The HVAC system may include an HVAC unit configured to condition an air flow via an evaporator, a furnace, a heating coil, a chiller system, another type of HVAC system, or any combination thereof, and to provide the conditioned air flow (e.g., a heated air flow, a cooled air flow) to the space. For example, the HVAC unit may be fluidly coupled to the space via an air distribution system, such as a system of ductwork, which extends between the HVAC unit and the space. As such, one or more fans or blowers of the HVAC system may be operable to direct a supply of conditioned air from the HVAC unit, through the ductwork, and into the spaces within the building.
Typically, the HVAC system includes one or more diffusers (e.g., diffuser assemblies) that may be fluidly coupled to the ductwork and configured to facilitate distribution of air into the rooms or spaces of the building. For example, the diffusers may be positioned adjacent to ceilings of the rooms or spaces and may be configured to discharge air from the ductwork into the spaces. In many cases, the diffusers operate to diffuse the discharged air into the rooms of spaces of the building. The diffusers may discharge the air into the spaces at least partially in a generally horizontal direction, at least partially in a general vertical direction, or both. To this end, the diffuser may include a frame and a plurality of blades coupled to the frame. The plurality of blades may be oriented in particular arrangement to generate and/or provide one or more air flow characteristics of the air flow discharged by the diffuser. For example, the plurality of blades may be arranged to provide a desired flow rate, flow direction, dispersion, velocity, diffusion, and/or other characteristic of the air flow. Unfortunately, existing diffusers are susceptible to various drawbacks. For example, existing diffusers may be time consuming, difficult, and/or expensive to manufacture, may provide an aesthetically undesirable appearance, and so forth. In many instances, a substantial amount of welding is involved in the manufacture and assembly of existing diffusers, which generates undesirable greenhouse gas emissions. Accordingly, present embodiments are directed to diffuser assemblies that rectify and/or address the foregoing drawbacks. For example, presently disclosed embodiments include diffuser assemblies that may be manufactured and assembled with a substantially reduced amount of welding, which reduces corresponding greenhouse gas emissions.
Turning now to the drawings,
In the illustrated embodiment, a building 10 is air conditioned by an HVAC system 12 having an HVAC unit 14. The building 10 may be a commercial structure or a residential structure. As shown, the HVAC unit 14 is disposed on the roof of the building 10; however, the HVAC unit 14 may be located in other equipment rooms or areas adjacent the building 10. The HVAC unit 14 may be a single package unit containing other equipment, such as a blower, integrated air handler, and/or auxiliary heating unit. In other embodiments, the HVAC unit 14 may be part of a split HVAC system, which includes an outdoor HVAC unit and an indoor HVAC unit.
The HVAC unit 14 may be an air cooled device that implements a refrigeration cycle to provide conditioned air to the building 10. Specifically, the HVAC unit 14 may include one or more heat exchangers across which an air flow is passed to condition the air flow before the air flow is supplied to the building 10. In the illustrated embodiment, the HVAC unit 14 is a rooftop unit (RTU) that conditions a supply air stream, such as environmental air and/or a return air flow from the building 10. The HVAC unit 14 may provide a variety of heating and/or cooling functions, such as cooling only, heating only, cooling with electric heat, cooling with dehumidification, cooling with gas heat, or cooling with a heat pump. For example, in certain embodiments, the HVAC unit 14 may be a heat pump that provides both heating and cooling to the building with one refrigeration circuit configured to operate in different modes. In other embodiments, the HVAC unit 14 may include one or more refrigeration circuits for cooling an air stream and a furnace for heating the air stream.
In any case, after the HVAC unit 14 conditions the air, the air may be supplied to the building 10 via ductwork 16 extending from the HVAC unit 14 and throughout the building 10. For example, the ductwork 16 may extend to various individual floors, rooms zones, or other sections or spaces of the building 10. In the illustrated embodiment, a plurality of diffuser assemblies 18 is coupled to the ductwork 16. As discussed in detail herein, the diffuser assemblies 18 may direct the conditioned air into the various spaces of the building 10 in a manner that improves air distribution and/or air dispersion across the spaces.
In some embodiments, a control device 20, one type of which may be a thermostat, may be used to designate the temperature of the conditioned air supplied by the HVAC unit 14. The control device 20 also may be used to control the flow of air through the ductwork 16. For example, the control device 20 may be used to regulate operation of one or more components of the HVAC unit 14 or other components, such as dampers and fans, within the building 10 that may control flow of air through and/or from the ductwork 16. In some embodiments, other devices may be included in the system, such as pressure and/or temperature transducers or switches that sense the temperatures and pressures of supply air, return air, and so forth. Moreover, the control device 20 may include computer systems that are integrated with or separate from other building control or monitoring systems, and even systems that are remote from the building 10.
In an installed configuration of the diffuser assembly 32 within the building 10, the diffuser assembly 32 may be positioned near a ceiling 38 of the space 22. Specifically, in the installed configuration, the diffuser assembly 32 may be coupled to the ceiling 38 or to a support structure suspended from the ceiling 38, such as an array of ceiling tiles. In some embodiments, in the installed configuration, the diffuser assembly 32 may be positioned and/or oriented such that an axis 40 (e.g., a central axis) extending through the inlet 34 is aligned generally parallel to a direction of gravity. For clarity, it should be understood that the axis 40 may extend along a direction of air flow through the inlet 34. Moreover, it should be understood that, as used herein, discussions relating to axes (and/or directions) being “generally” parallel to or aligned with other reference axes (and/or reference directions) are intended to denote that the axes are within a threshold orientational range of the reference axes, such as within one degree of, within five degrees of, or within ten degrees of the reference axes.
In some embodiments, the diffuser assembly 32 may be configured to discharge the supply air 30 into the space 22 along a first direction 44, which extends generally parallel to the axis 40, or along one or more second directions 46, which extend oblique to (e.g., radially or laterally from) the axis 40. For clarity, as used herein, discussions relating to axes (and/or directions) being oblique to other reference axes (and/or reference directions) may denote that the axes are angled from the reference axes by threshold orientational range, such as, for example, more than approximately 15 degrees. Thus, as a non-limiting example, it should be appreciated that respective angles 48 between the axis 40 and the second directions 46 may be between approximately 15 degrees and approximately 45 degrees, between approximately 30 degrees and approximately 60 degrees, or between approximately 45 degrees and approximately 90 degrees. As used herein, the term “approximately,” when used with respect to discussions of an angle or axis, is intended to denote that the angle or axis is within, for example, two degrees of the discussed value of the angle or axis. In view of the foregoing, it should be appreciated that, in the installed configuration, the diffuser assembly 32 may guide discharge the supply air flow 30 into the space 22 along a vertical direction (e.g., first direction 44) that extends generally toward a floor 50 of the space 22, or at least partially along one or more lateral directions (e.g., one or more second directions 46) that extend generally at an angle (e.g., an oblique angle) relative to the axis 40.
As described in further detail below, the diffuser assembly 32 includes one or more features that enable manufacture and assembly of the diffuser assembly 32 with improved efficiency, such as reduced labor and/or reduced costs, and with improved aesthetics. While existing diffusers are typically assembled via extensive welding of components to one another, features of the diffuser assembly 32 described herein enable manufacture and assembly of the diffuser assembly 32 with substantially reduced amounts of welding, which enables a substantial reduction in greenhouse gas emissions generated during manufacture and assembly of the diffuser assembly 32. For example, present embodiments of the diffuser assembly 32 include a blade assembly having a support rail with a plurality of slots formed therein and a plurality of blades configured to extend within the plurality of slots. The support rail engages with the plurality of blades via the plurality of slots to enable retention of the plurality of blades in a desired orientation (e.g., angular orientation) that enables desired flow of air through the diffuser assembly 32. As described below, the plurality of blades and the plurality of slots may each include respective geometries that correspond with one another to enable engagement between the support rail and the plurality of blades and retention (e.g., fixed positioning) of the plurality of blades relative to the support rail. The blade assembly (e.g., support rail and plurality of blades) may be coupled to a frame of the diffuser assembly 32 to support and retain the blade assembly in a desired orientation within an air flow path extending through the diffuser assembly 32. In this manner, the diffuser assembly 32 may be manufactured and assembled with substantially reduced amounts of labor and limited use of welding processes. The present techniques also enable more reliable manufacture and assembly of the diffuser assembly 32, as well as improved aesthetics of the diffuser assembly 32 in an assembled configuration. Details of certain embodiments of the diffuser assembly 32 are discussed in further detail below. To facilitate the following discussion, the diffuser assembly 32 and components thereof may be described with reference to a first lateral axis 80, a second lateral axis 82, and a vertical axis 84, which is oriented relative to a direction of gravity.
As mentioned above, the diffuser assembly 32 also includes a blade assembly 110 (e.g., blade core, diffuser core) configured to couple (e.g., mount, attach) to the frame 100. The blade assembly 110 includes one or more support rails 112 (e.g., tie bars, support beams, braces, supports, struts, etc.) and a plurality of blades 114 (e.g., wings) coupled to the one or more support rails 112. In accordance with the present techniques, the blade assembly 110 (e.g., support rails 112 and blades 114) are configured to be assembled to one another with improved efficiency (e.g., reduced time and/or labor), at reduced costs, and with reduced use of welding processes. To this end, the one or more support rails 112 may each include a plurality of slots formed therein, and each blade 114 of the plurality of blades 114 may extend through a corresponding slot of the plurality of slots of each support rail 112. The blades 114 and the slots may each have respective geometries that correspond (e.g., match, associate, correlate, coordinate) with one another to enable engagement between the support rail 112 and the blades 114. More specifically, engagement between the support rail 112 and the blades 114 via the slots of the support rail 112 may retain the blades 114 in a desired orientation of the blades 114 within the air flow path 102. For example, the blades 114 and the support rail 112 may engage with one another to maintain an orientation (e.g., angular orientation, oblique orientation) of the blades 114 relative to a direction of air flow 116 through the diffuser assembly 32. In some embodiments, the blades 114 may be further secured (e.g., attached, fixed) to the one or more support rails 112 via spot welds, brazes, adhesives, or other localized securement technique. Indeed, the blade assembly 110 may be assembled with substantially reduced amounts of welding relative to existing diffusers, which may reduce generation of greenhouse gas emissions during assembly of the diffuser assembly 32. Additionally details of the support rails 112 and the blades 114 are described further below.
The blade assembly 110 may be coupled to the frame 100 to position and retain the blade assembly 110 within the air flow path 102 extending through the frame 100. In the illustrated embodiment, the blade assembly 110 is coupled to the collar 104 via the support rails 112. In particular, each support rail 112 includes extensions 118 (e.g., prongs, tines, projections) formed at opposite ends of the support rail 112. The extensions 118 may extend through corresponding apertures 120 formed in the collar 104. For example, a first segment 122 (e.g., section, portion) of the collar 104 may include apertures 120 configured to receive extensions 118 at one end of the support rails 112, and a second segment 124 (e.g., section, portion) of the collar 104, opposite the first segment 122 (e.g., relative to the air flow path 102) may include apertures 120 configured to receive extensions 118 at another end of the support rails 112. In some embodiments, the diffuser assembly 32 may include respective springs 126 (e.g., biasing elements) disposed about one or more of the extensions 118 to enable spring-loading of the blade assembly 110 within the frame 100. That is, each spring 126 may engage with a segment of the collar 104 and a main body 128 of the support rail 112 to place the spring 126 in compression and retain the blade assembly 110 within the air flow path 102 (e.g., within or internal to the collar 104). The springs 126 may also facilitate convenient, simple, and efficient installation of the blade assembly 110 with within the frame 100 and removal of the blade assembly 110 from the frame 100. Indeed, the extensions 118 and the springs 126 may enable removable coupling (e.g., removable securement, removable attachment, removable assembly) of the blade assembly 110 with the frame 100 without the use of welding. However, it should be appreciated that the blade assembly 110 may be coupled to the frame 100 in other manners, examples of which are described below.
In accordance with the present techniques, the main body 128 of each support rail 112 includes a plurality of slots 154 (e.g., cutouts, slits, notches, grooves, etc.) formed therein. Correspondingly, each blade 114 includes a retention portion 156 (e.g., hook portion, retainer portion, locking portion, engagement portion, interlocking portion, engagement portion) extending from a main portion 158 (e.g., air guiding portion, blade portion) of the blade 114. The retentions portions 156 of the blades 114 are configured to extend within one of the slots 154 formed in each of the support rails 112 to enable engagement (e.g., coupling, assembly, securement) between the support rails 112 and the blades 114. To position the retention portions 156 within the slots 154, the support rails 112 and/or the blades 114 may be translated relative to one another along the second lateral axis 82.
As described further below, the slots 154 and the retention portions 156 may have corresponding or matching geometries that enable retention of the blades 114 with the support rails 112. In an assembled configuration, the blades 114 may be suspended within the frame 100 (e.g., within the air flow path 102) by the support rails 112. To this end, the slots 154 may be formed in a base edge 160 (e.g., lower edge, relative to the vertical axis 84) of the corresponding support rail 112, and the retention portions 156 may extend from the main portions 158 of the blades 114 at least partially in a vertical direction (e.g., at least partially along the vertical axis 84). As a result, the main portions 158 of the blades 114 may extend at least partially downward (e.g., relative to gravity, relative to the vertical axis 84) from the support rails 112 in an assembled configuration of the blade assembly 110 and/or the diffuser assembly 32. Additionally, in the illustrated embodiment, the main portions 158 of the blades 114 extend at least partially in a first direction 162 along the first lateral axis 80. In other words, the main portions 158 of the blades 114 extend at least partially downward along the vertical axis 84 and at least partially in the first direction 162 along the first lateral axis 80. Thus, the main portions 158 (e.g., at least a respective section of each main portion 158) may be oriented at an oblique angle relative to the direction of air flow 116 through the diffuser assembly 32.
The engagement between the retention portions 156 and the support rails 112 via the slots 154 may enable secured positioning of each blade of the plurality of blades 114 in a respective desired orientation, such as a desired angular orientation (e.g., at an angle, such as an oblique angle and/or a non-zero angle, relative to the direction of air flow 116 and/or relative to the vertical axis 84). In the illustrated embodiment, each blade 114 is arranged in a common angular orientation (e.g., extending at least partially downward along the vertical axis 84 and at least partially in the first direction 162 along the first lateral axis 80). Thus, the blade assembly 110 of the illustrated embodiment may be utilized with an embodiment of the diffuser assembly 32 configured as a one-way diffuser (e.g., one discharge direction of air flow). However, in other embodiments, the plurality of blades 114 may be arranged in a plurality of subsets of blades 114, and each subset may have an angular orientation (e.g., a first angular orientation) that is different from an angular orientation (e.g., a second angular orientation). For example the plurality of blades 114 may include a first subset of blades 114 extending at least partially downward along the vertical axis 84 and at least partially in the first direction 162 along the first lateral axis 80 (e.g., a first angular orientation) and a second subset of blades 114 extending at least partially downward along the vertical axis 84 and at least partially in a second direction 164, opposite the first direction 164, along the first lateral axis 80 (e.g., a second angular orientation). In such an embodiment, the blade assembly 110 may be utilized with an embodiment of the diffuser assembly 32 configured as a two-way diffuser (e.g., two discharge directions of air flow). To this end, the slots 154 of the support rails 112 corresponding to the second subset of blades 114 may have similar geometries but may be oriented in an opposite direction (e.g., along the first lateral axis 80) relative to that of the slots 154 corresponding to the second subset of blades 114). However, it should be appreciated that the present techniques may be similarly implemented with other subsets of blades 114 having different angular orientations to enable assembly of diffuser assemblies 32 configured as a three-way diffuser, a four-way diffuser, and so forth.
In any case, the slots 154 of each support rail 112 are arrayed (e.g., spaced apart from one another) along the main body 128 and along the first lateral axis 80. Thus, in an assembled configuration of the blade assembly 110, the blades 114 coupled to (e.g., engaged with) and retained by the support rails 112 may also be arrayed and/or spaced apart from one another to establish air flow passages 166 extending between adjacent blades 114 to enable conveyance and guidance of air flow through the diffuser assembly 32 and to discharge the air flow from the diffuser assembly 32 in one or more desired directions (e.g., angular directions and/or at an oblique angle, relative to the vertical axis 84). Accordingly, a spacing, configuration, number, arrangement, and/or other characteristic of the slots 154 may be selected based on a desired arrangement of the blades 114 of the diffuser assembly 32 in an assembled, installed, and/or operating configuration.
As described above, each support rail 112 includes a plurality of slots 154 formed therein, and each blade 114 includes the retention portion 156 configured to extend within one of the slots 154 of each support rail 112. To this end, the slots 154 may include a first geometry, and the retention portions 156 of the blades 114 may include a second geometry that corresponds to (e.g., matches with, is associated with, correlates with, complements) the first geometry of the slots 154. As a result, the retention portion 156 may extend within a corresponding one of the slots 154 of each support rail 112 and may engage with the support rail 112 (e.g., the main body 128) to enable retention of the blade 114 (e.g., relative to the support rail 112, relative to the frame 100) in a desired and/or assembled configuration. A number of the slots 154 formed in each support rail 112 may correspond (e.g., equal) a number of the blades 114 supported by the support rails 112.
In the illustrated embodiment, the first geometry of each slot 154 is generally defined by a first groove 180 (e.g., slit, notch, channel, passage, segment) formed in the main body 128 and a second groove 182 (e.g., slit, notch, channel, passage, segment) formed in the main body 128 and extending cross-wise to the first groove 180. Specifically, the first groove 180 extends from the base edge 160 and into the main body 128 along the vertical axis 84, and the second groove 182 extends from the first groove 180 (e.g., at approximately a 90 degree angle) and into (e.g., through) the main body 128 along the first lateral axis 80 (e.g., toward the first end 150 of the support rail 112). In this way, the first groove 180 and the second groove 182 cooperatively define a generally L-shaped configuration (e.g., L-shape, inverted L-shape, L-shaped geometry). However, in other embodiments, the slots 154 may include any suitable number and/or arrangement of grooves. For example, the slots 154 may have an L-shape, a T-shape, a mirrored L-shape (e.g., relative to the second lateral axis 82), an inverted L-shape, an inverted T-shape, a zigzag configuration, a linear configuration, a non-linear configuration, a geometric configuration, a non-geometric configuration, an acute angle configuration, an oblique angle configuration, another suitable configuration, or any combination thereof.
To enable retention of the blades 114 within the slots 154 and by the support rails 112, the retention portions 156 of the blades 114 may have a profile, shape, geometry, dimension, size, arrangement, and/or configuration that corresponds to (e.g., matches) that of the slots 154. For example, in the illustrated embodiment, the retention portion 156 includes a first segment 184 extending generally along the vertical axis 84 and a second segment 186 extending from the first segment 184 generally along the first lateral axis 80. Thus, the retention portion 156 also defines a generally L-shaped configuration corresponding to that of the slots 154. In this way, the blade 114 may translate along the second lateral axis 82, relative to the support rails 112, to position the retention portion 156 within the slots 154. In an assembled configuration of the blade assembly 110, the first segment 184, the second segment 186, or both may engage with edges (e.g., internal edges) of the main body 128 defining the slots 154, such that the blade 114 may be retained by the support rails 112 in a desired orientation (e.g., angular orientation). For example, engagement (e.g., physical engagement, abutment) between the retention portion 156 and the edges of the main body 128 defining the slot 154 may block pivoting and/or rotation of the blade 114 (e.g., relative to the support rails 112) about the second lateral axis 82. Thus, an angular orientation of the blade 114, and particularly an angular orientation of the main portion 158 of the blade 114 (e.g., relative to the direction of air flow 116) may be maintained. The engagement between the retention portion 156 and the edges of the main body 128 defining the slot 154 may also block translation of the blade 114 relative to the support rails 112 along the first lateral axis 80, along the vertical axis 84, or both. To further provide securement (e.g., fixed attachment) of the blade 114 to the support rails 112, the blade 114 and/or the support rails 112 may be at least partially fixed relative to one another via one or more spot welds 188 (e.g., tack welds). However, it should be appreciated that the spot welds 188 may be formed or established via substantially reduced welding operations, particularly as compared to existing diffusers. Additionally or alternatively, other retention features and/or mechanisms may be utilized to further secure the blades 114 to the support rails 112 with the retention portions 156 positioned within the slots 154. For example, the retention portions 156 may be secured within the slots 154 in a desired position, orientation, and/or configuration via an interference fit, a snap fit, a friction fit, an adhesive, a fastener, a clip, another retention feature, or any combination thereof. In some embodiments, the blades 114 (e.g., the retention portions 156) may include one or more extensions (e.g., tabs) extending from the first segment 184, the second segment 186, or both to abut the main body 128 of the support rail 112 and/or to capture the main body 128 of the support rail 112 therebetween to block undesired translation of the blade 114 relative to the support rails 112 and along the second lateral axis 82 after assembly of the blade assembly 110 and/or after installation of the blade assembly 110 with the frame 100.
As similarly described above, in some embodiments, the support rails 112 may have different subsets of slots 154, with each subset having a corresponding geometry, s shape, configuration, and/or arrangement. For example, in an embodiment of the diffuser assembly 32 configured as a two-way diffuser, a first subset of the slots 154 may have the second groove 182 extending from the first groove 180 along the first lateral axis 80 toward the first end 150 of the support rail 112, and a second subset of the slots 154 may have the second groove 182 extending from the first groove 180 along the first lateral axis 80 toward the second end 152 of the support rail 112. Thus, the respective slots 154 of the first subset and the second subset may be mirrored relative to one another (e.g., about the second lateral axis 82). The retention portions 156 of the blades 114 may therefore extend within corresponding slots 154 of the support rails 112 to position a first subset of the blades 114 in a first angular orientation and to position a second subset of the blades 114 in a second angular orientation. In any case, the respective profiles or geometries of the slots 154 may generally correspond with and/or match the respective profiles or geometries of the retention portions 156 of the blades 114 to enable extension of the retention portions 156 within the slots 154 to retain a desired position of blades 114 relative to the support rails 112 (e.g., with substantially reduced reliance on labor-intensive processes, such as welding).
In the illustrated embodiment, the main portion 158 of the blade 114 includes a primary segment 206 (e.g., air guiding surface, air deflector, guidance portion, first segment) and a secondary segment 208 (e.g., distal segment, second segment). The primary segment 206 extends from the retention portion 156 (e.g., the first segment 184) at least partially along the first lateral axis 80 (e.g., in the first direction 162) and at least partially along the vertical axis 84. Thus, in an assembled and installed orientation (e.g., within the ceiling 38), the primary segment 206 extends at an angle (e.g., an angular orientation, an oblique angle) relative to the direction of air flow 116 into the diffuser assembly 32. The angle at which the primary segment 206 is oriented may be based on any suitable parameter, characteristic, or input, such as an installed location of the diffuser assembly 32, a type of the diffuser assembly 32, a desired air flow pattern generated by the diffuser assembly 32, a type of the space, and so forth. The secondary segment 208 is disposed at the second end 202 of the blade 114 and may extend from the primary segment 206 in any suitable orientation, such as at an angle (e.g. oblique angle). In the illustrated embodiment, the secondary segment 208 extends generally along the first lateral axis 80 and may facilitate diffusion and/or dispersion of the air flow into the space as the air flow is discharged from the diffuser assembly 32. It should be appreciated that other embodiments of the main portion 158 of the blade 114 may have any number, orientation, dimension, arrangement, and/or configuration of segments.
The blade 114 may be formed from any suitable material, such as sheet metal, aluminum, a polymer, a plastic, a composite, or any combination thereof. Additionally, in some embodiments, the primary segment 206 and the secondary segment 208 may be integrally formed with one another (e.g., as a single piece), the main portion 158 and the retention portion 156 may be integrally formed with one another (e.g., as a single piece), or both. For example, the main portion 158, the retention portion 156, and respective segments thereof may be formed from a single piece of material, such as via a bending or forming process.
Each subset of the blades 114 is oriented in a common angular orientation with other blades 114 in the same subset, and the respective angular orientations of the blades 114 of the various subsets are different from one another. In particular, the first subset of blades 220 is oriented at least partially along the vertical axis 84 (e.g., in a downward direction) and at least partially along the first lateral axis 80 in the first direction 162, and the second subset of blades 224 is oriented at least partially along the vertical axis 84 (e.g., in a downward direction) and at least partially along the first lateral axis 80 in the second direction 164. Additionally, the third subset of blades 228 is oriented at least partially along the vertical axis 84 (e.g., in a downward direction) and at least partially along the second lateral axis 82 in a third direction 236, and the fourth subset of blades 232 is oriented at least partially along the vertical axis 84 (e.g., in a downward direction) and at least partially along the second lateral axis 82 in a fourth direction 238, opposite the third direction 236. Thus, the blade assembly 110 of the illustrated embodiment may be configured to discharge air flow in four different directions and may be implemented with an embodiment of the diffuser assembly 32 configured as a four-way diffuser. However, as noted above, other embodiments of the diffuser assembly 32 and/or the blade assembly 110 may have other number of subsets of blades 114 configured to discharge air from the diffuser assembly 32 in other numbers of directions. For example, the blade assembly 110 may include three subsets of blades 114, each oriented in a respective angular orientation, configured to discharge air flow in three different directions and may be implemented with an embodiment of the diffuser assembly 32 configured as a three-way diffuser.
The blades 114 of each subset and the corresponding support rail 112 may include features similar to those described above to enable securement of the blades 114 and the support rail 112 to one another and to enable retention of the blades 114 of each subset in a corresponding desired orientation (e.g., angular orientation). That is, each blade 114 of each subset may include the retention portion 156, and each support rail 112 may include the slots 154 formed therein to enable engagement between the support rail 112 and the blades 114 of the corresponding subset. In some embodiments, one or more of the blades 114 (e.g., an innermost blade, an outermost blade, or both) of each subset may be spot-welded to the corresponding support rail 112, as similarly described above, to further reduce an amount of welding performed to assemble the diffuser assembly 32. In other embodiments, all blades 114 of each subset may be spot-welded to the corresponding support rail 112.
As shown, the respective blades 114 of each subset of blades 114 may abut and/or may extend adjacent to the blades 114 of an adjacent subset of blades 114. For example, the blades 114 of the first subset of blades 220 extend and/or are positioned adjacent to the blades 114 of the third subset of blades 228 and the fourth subset of blades 232. Similarly, the blades 114 of the third subset of blades 228 extend and/or are positioned adjacent to the blades 114 of the first subset of blades 220 and the second subset of blades 224, the blades 114 of the second subset of blades 224 extend and/or are positioned adjacent to the blades 114 of the third subset of blades 228 and the fourth subject of blades 232, and so forth. Accordingly, the corresponding blades 114 of adjacent subsets may be coupled to one another to improve a structural rigidity of the blade assembly 110 and/or to reduce bypass of air flow between blades 114 of adjacent subsets. The corresponding blades 114 of adjacent subsets may be coupled to one another in any suitable manner, such as via attachment brackets 240 (e.g., chevron brackets, joints, securement panels). In some embodiments, the attachment brackets 240 may be spot-welded to the corresponding blades 114 of adjacent subsets.
The diffuser assembly 32 (e.g., blade assembly 110) of the illustrated embodiments also includes additional elements configured to enable assembly of the diffuser assembly 32 with substantially reduced amounts of labor and limited use of welding processes. As shown, the diffuser assembly 32 includes a central cone 260 (e.g., center support) with a bracket 262 (e.g., support bracket) secured thereto, such as via one or more spot-welds. One or more of the blades 114 of the blade assembly 110 may be attached to the bracket 262. For example, a respective innermost blade 264 (e.g., relative to the first lateral axis 80 and/or the second lateral axis 82) of the third subset of blades 228 and the fourth subset of blades 232 may be attached to the bracket 262, such as via corresponding spot-welds. In this way, an amount of welding utilized to assemble the diffuser assembly 32 may be further reduced. The respective blades 114 of the first subset of blades 220 and the second subset of blades 224 may not be fixedly attached directly to the central cone 260 and/or the bracket 262. As will be appreciated, securement of adjacent subsets of blades 114 via the attachment brackets 240 may provide structural support and rigidity to maintain a desired arrangement of the components of the blade assembly 110 in an assembled configuration.
The illustrated embodiments of the diffuser assembly 32 also include protrusion tabs 266 having corresponding protrusions 268 (e.g., prongs, tines). The protrusion tabs 266 may be attached to one or more of the blades 114 of the blade assembly 110 (e.g., via spot-welds), and the protrusion tabs 266 (e.g., the protrusions 268) may function in a manner similar to that of the extensions 118 described above. That is, the protrusions 268 may extend into corresponding apertures 129 of the frame 100 in an assembled configuration of the diffuser assembly 32. To this end, one or more of the protrusion tabs 266 may include one or more springs 126 disposed about the corresponding protrusions 268 to enable a spring-loaded engagement between the blade assembly 110 and the frame 100 in an assembled configuration of the diffuser assembly 32.
As set forth above, embodiments of the present disclosure may provide one or more technical effects useful in manufacturing and/or assembly diffuser assemblies. For example, the diffuser assembly may include one or more features that enable manufacture and assembly of the diffuser assembly with improved efficiency, such as reduced labor and/or reduced costs, and with improved aesthetics. While existing diffusers are typically assembled via extensive welding of components to one another, features of the diffuser assembly described herein enable manufacture and assembly of the diffuser assembly with substantially reduced amounts of welding, which enables a substantial reduction in greenhouse gas emissions generated during manufacture and assembly of the diffuser assembly. For example, present embodiments of the diffuser assembly include a blade assembly having a support rail with a plurality of slots formed therein and a plurality of blades configured to extend within the plurality of slots. The support rail engages with the plurality of blades via the plurality of slots to enable retention of the plurality of blades in a desired orientation (e.g., angular orientation) that enables desired flow of air through the diffuser assembly. The plurality of blades and the plurality of slots may each include respective geometries that correspond with one another to enable engagement between the support rail and the plurality of blades and retention (e.g., fixed positioning) of the plurality of blades relative to the support rail. The blade assembly (e.g., support rail and plurality of blades) may be coupled to a frame of the diffuser assembly to support and retain the blade assembly in a desired orientation within an air flow path extending through the diffuser assembly. In this manner, the diffuser assembly may be manufactured and assembled with substantially reduced amounts of labor and limited use of welding processes. The present techniques also enable more reliable manufacture and assembly of the diffuser assembly, as well as improved aesthetics of the diffuser assembly in an assembled configuration.
While only certain features and embodiments have been illustrated and described, many modifications and changes may occur to those skilled in the art, such as variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, such as temperatures and pressures, mounting arrangements, use of materials, colors, orientations, and so forth, without materially departing from the novel teachings and advantages of the subject matter recited in the claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the disclosure.
Furthermore, in an effort to provide a concise description of the exemplary embodiments, all features of an actual implementation may not have been described, such as those unrelated to the presently contemplated best mode, or those unrelated to enablement. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation specific decisions may be made. Such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure, without undue experimentation.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202321048660 | Jul 2023 | IN | national |
