FIELD
This disclosure relates generally to a louver assembly. The louver assembly may be used, for example, with a packaged terminal air conditioner (PTAC) system or in any location in a building that requires a louver. More specifically, the louver assembly includes a louver frame and a blade/strut panel that can be removably mounted to the louver frame for easy maintenance and repair and/or assembly. The louver assembly may also include one or more diffusers that can be variably mounted to the louver frame such that the louver assembly can be used with a variety of PTAC units with different specifications.
BACKGROUND
PTAC systems provide personalized temperature control, while maintaining low initial costs and simplified installation, for buildings such as hotels and small multifamily condominium buildings. Louvers are often installed from the outside of the building to cover the PTAC unit and improve the functionality and aesthetics.
While PTAC units are typically of generally uniform size, typically, 42 by 16 inches, each PTAC manufacturer may specify different mounting configurations for the PTAC unit and a louver must be selected to fit a predetermined configuration, e.g., predetermined locations for diffusers and/or predetermined heights for struts on which blades are to be mounted. Also, while typical PTAC units are longer in width than in height, the dimensions may vary. Furthermore, a PTAC unit may be longer in height than width, and such PTAC units are sometimes referred to as VTAC units. Both units are referred to as PTAC units for purposes of this application.
Often PTAC units to be used in a building are specified early in the design and construction of the building, and louvers are ordered and/or manufactured for the specified units. If, however, the specified PTAC units change or are unavailable, and different PTAC units are used, the louver's specifications may change as well. For example, known louver designs have the louvers and diffusers mounted to the same component and/or vertical strut and diffusers are positioned for a particular PTAC unit to help intake and exhaust of air from the PTAC unit. If the diffusers need to be mounted in a different location than originally specified and the louver design needs to change, it may cause delays and/or add extra cost.
In addition, current louver designs and methods of attaching the louver blades to struts, involve struts that have been notched out to receive the blade and placing blades into the notches. This often results in blades that are not fastened securely and/or have spacing that is not uniform and is unsightly. The structural integrity of the strut is also compromised when notches are formed in the strut. Furthermore, current methods of attaching the louver blades and diffusers to the same strut, often resulting in rattling when the PTAC unit is operated.
Current techniques for manufacturing blade/strut assemblies also result in blade spacing that does not fit the vertical space within a particular frame properly and therefore becomes difficult to install, or looks poor due to uneven spacing of blades, especially at the top or bottom of the frame. Often, due to inadequate spacing of blades on struts, manufacturers use half blades at the bottom and/or double blades at the top to mask top/bottom fitment issues which is very noticeable.
Further, current louver assemblies lack easy removal of the louver panel from the PTAC unit or frame to allow for ease of maintenance, repair, or replacement.
The assembly described herein provides advantages to existing louver assemblies for use with PTAC systems.
SUMMARY
One aspect of the invention includes an assembly with a removable blade/strut panel for ease of maintenance and repair.
Yet another aspect of the invention includes a blade/strut panel that has precise blade spacing with blades that are securely mounted to the struts. The precise blade spacing is accomplished by a new manufacturing method that may include the steps of determining the number of blades to be used for a particular panel, determining the desired spacing and locations for the blades on the strut, attaching a first blade on the strut at a first predetermined location, moving the panel to a second predetermined location for blade attachment, placing the blade at the second location and attaching the blade at that location. The process is continued until blades are attached at all predetermined locations. The blades may also be attached by clinch rivets and without notches in the blade. The use of clinch rivets not only provides for a strong attachment of the blade to the strut, it also eliminates the need for notches in the struts.
Another aspect includes a louver assembly with diffusers that may be mounted in a variety of positions along the frame which provides flexibility and allows the assembly to be used with a variety of PTAC units that may have different mounting specifications.
Other advantages of the present invention will become readily apparent from the following detailed description. The invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the invention. Accordingly, the drawing and description are illustrative in nature, not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of the disclosed embodiments will become more readily appreciated by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a front perspective view of an assembled louver assembly.
FIG. 2 is a rear view of an assembled louver assembly.
FIG. 3 is an exploded view of a louver assembly.
FIG. 4 is a top view of a blade/strut panel.
FIG. 5 is a sectional view of a louver frame, taken across the line 5-5 of FIG. 3.
FIG. 6 is a top view of two diffusers.
FIG. 7 is a sectional view of an assembled louver assembly, with a blade/strut panel, a louver frame and diffusers, taken across the line 7-7 of FIG. 2.
FIG. 8 is an exploded side view of a blade/strut panel, a retainer and a shoe.
FIG. 9A is a sectional view the louver frame, taken across the line 9A-9A of FIG. 3.
FIG. 9B is a sectional view of the front of the louver frame, taken across the line 9B-9B of FIG. 3.
FIG. 9C is a rear view of the section of the louver frame shown in FIG. 9B.
FIG. 10 is a sectional view of an assembled blade/strut panel and louver frame, taken along the line 10-10 of FIG. 2.
FIG. 11 is a rear perspective view of a shoe for use with a blade/strut panel.
FIG. 12 is a front perspective view of a shoe for use with a blade/strut panel.
FIG. 13 is a top view of a strut for a blade/strut panel.
FIG. 14 is a sectional view of an upper corner section of a louver assembly, taken across the line 14-14 of FIG. 2.
FIG. 15 is a perspective view of a lower corner section of a louver frame, taken along the line 15-15 of FIG. 3.
FIG. 16 is a perspective view of a portion of a blade/strut panel.
FIG. 17 is a perspective cross-sectional view of a clinch rivet on a strut for a blade/strut panel.
FIGS. 18A-C are perspective views of various examples of blade/strut panels.
FIG. 19 is an exploded view of another example of a louver assembly.
DETAILED DESCRIPTION
In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without these specific details.
Turning now to FIGS. 1-3, an example of a louver assembly 100 is shown. While such an assembly is primarily described herein with respect to use with a PTAC unit, such an assembly may be used in applications that do not include a PTAC unit, and can be used more generally in any location where a louver is desired in a building. The louver assembly 100 may include several components, including a blade/strut panel 200, a louver frame 300 and one or more diffusers 400.
Generally, the blade/strut panel 200 includes a plurality of blades 202 suitably attached to one or more vertical struts 204, 206, 208. Any appropriate number of blades and struts may be used. The blades 202 may be spaced equidistant from each other vertically along the struts 204, 206, 208. In one example, and as discussed below in more detail, the blades 202 may be attached to the struts 204, 206 and 208, by clinch rivets which provide for a strong connection of the blade to the strut. Of course, other means of attaching the blades to the struts may be used, for example and without limitation, adhesives, fasteners, and/or any other suitable attachment means. The blades 202 may be made of, for example, extruded aluminum. One example of extruded aluminum is an alloy known as 6063. Such an alloy may be made with various different tempering. Similarly, the struts 204, 206 and 208 may also be made of, for example, extruded aluminum. The struts may be made from the same material and alloy and tempering as the blade or a different material or alloy or tempering. While three struts 204, 206 and 208 are shown in the example in FIGS. 2 and 3, a different number may be used in a blade/strut panel. Use of an extruded aluminum for the blades 202 and struts 204, 206 and 208 and clinch rivets to attach the blades 202, 206 and 208 to the struts 204 provide good strut integrity and strength. Of course, other materials may be used to make the blades and struts, such as roll formed steel, vinyl or any other appropriate material. As shown in FIG. 3, and described below in more detail, a panel retainer 210 and one or more shoes 212, may be used to position the blade/strut panel 200 within a cavity 322 (shown and described below with reference to FIGS. 9A-C) in the frame 300 prior to attaching the blade/strut panel 200 to the frame 300.
Generally, the louver frame 300, is mounted in an opening of a wall, and has a generally rectangular shape formed by two horizontal frame members 302 and 304, e.g., top and bottom frame member, and two vertical frame members 306 and 308, e.g., a left and right frame member. The frame members 302, 304, 306 and 308 may be thermally enhanced extrudates suitably attached to one another. The frame 300 may be attached to a sleeve of a PTAC unit by one or more fasteners, such as bolts 310. The PTAC unit sleeve 500 is shown in dashed lines in FIGS. 2, 5 and 7.
Generally, and as also shown in FIGS. 3 and 6, the diffusers 400 may include a plurality of blades 402 mounted on a vertical strut 404. In addition, a bracket 406 may be attached to the strut 404. The bracket 406 may be used to attach the diffuser 400 to the frame 300 with a fastener, such as a screw 408, as shown and described in more detail below. The diffusers 400 may be attached to the frame 300 on an opposite side of the frame 300 from the blade/strut panel 200.
Turning now to FIGS. 4 and 6, top views of the blade/strut panel 200 and diffusers 400 are shown. As shown in FIGS. 4 and 13, the struts 204, 206 and 208 of the blade/strut panel 200 have a channel 214. As shown, in FIG. 5, the frame 300 may be attached to the sleeve 500 of a PTAC unit by fasteners, such as bolts 310. As shown, the frame members 302, 304, 306 and 308 may have similar cross sections. The frame members 302, 304, 306 and 308 may each have a flange 312. As shown the flanges 312 extend inwardly from a generally flat wall portion 313 of the frame members and may form a rear wall of the frame. The flat wall portions 313 of the top and bottom frame members 302 and 304 and the flanges 312 of the top and bottom frame members 302 and 304 define a cavity 322 that is generally C-shaped. The flanges 312 of the top and bottom frame members 302 and 304 may include, or have attached to them, channels or races 314 in which the bolts 310 may slide into a desired position prior to securing the sleeve 500 to the frame 300, for example with a nut (not shown) threaded onto the bolt 310.
As shown in FIG. 7, the diffusers 400 may be attached to the frame 300 using fasteners, such as screws 408 through the strut 404 and/or the bracket 406. Preset holes 316 (shown in FIGS. 3 and 15) may be provided in the flanges 312 of the top and/or bottom frame members 302 and 304 for receiving the screws 408 for placement of the diffusers 400 in a predetermined position. Alternatively, holes may be drilled into the flanges 312 of the top and bottom frame members 302 and 304, at desired locations at the time of installation. Diffusers help accomplish proper air intake and exhaust air for a PTAC unit and must be placed in positions that are specific for the PTAC unit. Variable mounting options of the diffusers to the frame allows flexibility for the louver assembly to be used with various PTAC units.
Also, as shown in FIGS. 5 and 7, a backer rod 318 may be provided to maintain a consistent gap width between the sleeve 500 and walls 309 of the frame members 302, 304, 306 and 308, and a seal 320 of silicone or other appropriate material, may be added between the frame members and the PTAC sleeve 500, to provide a seal between the PTAC sleeve 500 and the frame 300.
Turning now to FIG. 8 the retainer 210 has a panel receiving cavity 216, a retainer blade 218, which, as shown, projects generally downwardly, and a flange, which, as shown, projects generally upwardly. The retainer blade 218 may be angled downwardly at the same angle as the blades on the blade/strut panel 200, so it appears as if it is the top blade of the assembly 100. The cavity 216 is sized and shaped to be placed over the top of the blade/strut panel 200.
As also shown in FIG. 8, one or more shoes 212 are sized and shaped to be received within the channel 214 in each of the vertical struts 204, 206, 208. The shoe 212 has a strut receiving portion 222, a blade support portion 224 and a base portion 226. As shown in FIGS. 11-13, the strut receiving portion 222 is sized and shaped to reciprocate with the channel 214 in a strut 204, 206 or 208 and receive the strut 204, 206 or 208 over the top of the receiving portion 222 of the shoe 212. The shoe 212 may be, for example, a one-piece injection molded component.
Turning now to FIG. 9A, the louver frame 300 is shown attached to the sleeve 500 of the PTC unit. The louver frame has a generally C-shaped frame cavity 322, defined by the flat portions wall of the top and bottom horizontal frame members 302 and 304 and the flanges 312 of those frame members. The flanges 312 of the two members form a rear wall of the frame 300. As also shown in FIG. 9A, FIG. 9B and FIG. 9C, the frame members may also have an angled wall portion 326 that extends from flat wall portion 313 of the frame member. The lower horizontal frame member 304 may also include a portion 328 that is curved inwardly and is part of a weep hole to allow moisture to exit the frame 300.
With reference to FIG. 10, the blade/strut panel 200 is shown assembled into the louver frame 300. After the retainer 210 is placed onto the top of blade/strut panel 200 and after one or more of the struts 204 of the blade/strut panel 200 are placed onto the strut receiving portion 222 of one of more shoes 212, the components are placed into the frame cavity 322, as shown in FIG. 10. The bottom blade 202 of the blade/strut panel 200 may rest on the blade support portion 224 of the shoe 212 or shoes. The retainer flange 220 may also be seated against the angled wall portion 326 of the top frame member 302. The retainer flange 220 may then be attached to the frame member 302, by a fastener, such as a screw 330, to secure the blade/strut panel 200 to the frame 300 within the cavity 322. In addition, the back of the strut receiving portion 222 of the shoes 212 may have a hole to allow the shoe 212 to be attached to the bottom frame member 304 by fasteners, such as screws 230 (shown in FIGS. 3 and 15), inserted from the inside of the frame through holes 232 in the bottom frame member 304 of the frame 300. Attaching the blade/strut panel 200 in this manner makes it possible to remove the panel 200 from the outside of the building, without removal of the PTAC unit, to allow for maintenance, or cleaning or the PTAC unit, maintenance of the PTAC sleeve seal, and repair or replacement of the blade/strut panel 200.
As shown in FIGS. 7 and 14, when the blade/strut panel 200 is placed or positioned in the cavity 322, the blade strut channel 214 fits over the race 314 in the frame 300.
FIG. 16 illustrates a portion of the blade/strut panel 200 with the blades 202 fastened to a strut 204 by clinch rivets 350. Using clinch rivets 350 to attach the blade 202 to the strut 204, provides for a strong, solid connection which may reduce rattling of the blades. FIG. 17 illustrates a cross section view of a clinch rivet 350 in a blade 202.
FIGS. 18A-C are perspective views of various examples of blade/strut panels 200 with various spacing of the blades on the struts. Each of the panels shows panels with 20 blades, but with different blade spacing or increments. The spacing shown in FIG. 18A may be 0.760 inches, the blade spacing in FIG. 18B may be 0.780 inches and the blade spacing in FIG. 18C may be 0.800 inches. In FIG. 18B, the top blade is compressed by half this nominal increment and the bottom blade is stretched by half the nominal increment. The different spacing allows a manufacturer to build louvers to any height with perfect top and bottom blade fitment into the louver frame.
Variable spacing allows for more precise and evenly spaced top and bottom blade placement based on the height of the assembly. Such placement is done by a manufacturing process that determines an appropriate spacing based on the height of the strut, then attaching the blades by clinch riveting at the appropriate positions. For example, the struts may be placed on a table in the desired positions, i.e., desired widths apart from each other and vertically aligned, and a machine may move the table into position relative to a machine to attach a first blade in a desired location. After the first blade is attached, the table may move the struts and attached blade into position to attach the next blade at the determined distance (e.g., 0.760 inches) before attaching the next blade to the struts. The process of moving the table with the struts and attached blades to the next position, can be done accurately by digitally controlled equipment and attachment of the blades may be done by clinch riveting the blade to the strut.
The size of the assembly components 200, 300 and 400, may vary based on the size of the wall opening in which the assembly is to be installed. For example, the overall height and width blade/strut panel 200 and the louver frame 300 may vary depending on the application. Typical PTAC units are 42 inches in width and 16 inches in height and require an opening of that size. The present assembly may however, be of any desired width and height, including an assembly that is longer in height than width. Accordingly, as shown in the example in FIG. 1, the blade/strut panel 200 and louver frame 300 may be designed for a wall opening the same size as the PTAC unit. Alternatively, for aesthetic or other reasons, the wall opening may be larger than needed for a typical PTAC unit. For example, as shown, in FIG. 19, a blade/strut panel with four vertical struts 502, 504, 506 and 508 is shown. The width from vertical strut 502 to vertical strut 506 may be, for example, 42 inches and is the width of the portion of the frame where the PTAC unit would be positioned. The distance from vertical strut 506 to vertical strut 508 may be, for example, 16 inches and is the portion of the frame where the PTAC unit is not positioned. A panel 510, such as a “blank-off” panel or an insulated panel, may be attached to the blade/strut panel to cover the portion of the frame where the PTAC unit will not be positioned. The width of the blade/strut panel may be the entire width of the frame, in this case, 58 inches. Of course, the dimensions of the louver assembly components can be varied to accommodate any size opening. Also, “blank-off” or insulated panels may be positioned on both or either side of the blade/strut panel.
Although the present technology has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred implementations, it is to be understood that such detail is solely for that purpose and that the technology is not limited to the disclosed implementations, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present technology contemplates that, to the extent possible, one or more features of any implementation can be combined with one or more features of any other implementation.
Patent Application
20250116418
