Programmable energy saving register vent

Abstract

A programmable vent for a duct used with a building environmental air temperature control system. The programmable vent includes a vent housing with a front face which has an inset, where the vent housing is configured to allow air flow from the duct. At least one louver is movably connected to the vent housing, an actuator is connected to the at least one louver, a controller module is removably attached to the vent housing and positioned in the inset, the controller module being connected to the actuator when positioned in the inset.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a perspective plan view of an embodiment of a building environmental air temperature control system according to the present invention, as installed in a home;

FIG. 2 is a perspective view of an embodiment of a programmable vent according to the present invention;

FIG. 3 is an exploded perspective view of the programmable vent of FIG. 2;

FIG. 4 is a front view of the controller module of FIG. 2;

FIG. 5 is a section view taken along section line 5-5 in FIG. 2, and shown with the louvers open;

FIG. 6 is the section view of FIG. 5 but shown with the louvers closed;

FIG. 7 is a section view taken along section line 7-7 in FIG. 2;

FIG. 8 is an exploded perspective view of the controller module of FIG. 4; and

FIG. 9 is an electrical schematic view of an embodiment of the programmable vent of FIG. 2.

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate one preferred embodiment of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION OF THE INVENTION

With initial reference to FIG. 1, there is shown a building environmental air temperature control system 10, such as an HVAC system, located in building 12. System 10 can include at least one of a heating system and a cooling system, such as furnace 14 connected to air conditioning compressor 16. Furnace 14 can typically be a forced air system including a burner/heat exchanger unit and a blower (all not shown), or alternatively a gravity system, or other system. Further, furnace 14 can include other elements such as controls and thermostats (also not shown). At least one duct 18 is connected to furnace 14. Programmable vents 20 are connected to corresponding ducts 18. System 10, and more particularly programmable vents 20, can be used during a daytime setting in a cooling, or summer, season; during a nighttime setting in a heating, or winter, season; or other configurations, for example: a daytime setting in a heating, or winter, season; or a nighttime setting in a cooling, or summer, season. Additional configurations are possible as dictated by user requirements, seasonal conditions, latitude, elevation, weather and other parameters.

Referring more particularly to FIGS. 2-9, programmable vent 20 includes a vent housing 22 and at least one louver 24 movably connected to housing 22. Housing 22 also includes a fixed aperture plate 26. Fixed aperture plate 26 can include fins 27 which also provide a directional control of air through programmable vent 20. An actuator 28 is connected to louvers 24 and housing 22. Actuator 28 can be in the form of a DC motor as is shown, and/or other elements.

A first plurality of electrical terminals 30 are connected to electric motor 28 via wires 32, and terminals 30 are fixedly connected to vent housing 22. Changing the polarity of the voltage on terminals 30 reverses the rotation of the shaft of motor 28. Controller module 34 is removably attached to vent housing 22. Controller module 34 includes a controller housing 36 and a controller unit 38 within controller housing 36. Controller unit 38 including a second plurality of electrical terminals 40 resiliently contacting motor terminals 30 when module 34 is mounted in vent housing 22. Controller unit 38 includes a circuit board 42 with motor controls 44 connected to terminals 40 to operate motor 28. Controller unit 38 also includes a controller 46, such as a microprocessor, application specific integrated circuit (ASIC) and/or other programmable controller devices, and can include other electronic devices as are shown particularly in FIG. 9.

Controller module 34 can further includes a display 48, a user input device 49 which has pushbuttons 50, 52, 54 (or other switch or input element types, such as a touchpad), display backlight 56, batteries 58 and associated wiring all electrically connected to circuit board 42 and controller 46. Controller module 34 can also include a front cover 60 with a hinged door 62 which provides access to user input device 49, and when closed, prevents inadvertent programming of vent 20, and battery cover 64.

Controller housing can be in a snap fit arrangement with vent housing 22. For example, the snap fit arrangement includes at least one resilient ramped projection 66 connected to controller housing 36, and at least one detent 68 in vent housing 22. Ramped projections 66 are insertable in a corresponding detent 68 when controller housing 36 is in the snap fit arrangement with vent housing 22. Vent housing 22 further includes a frame or inset 70 in which controller module 34 is inserted. Frame 70 includes at least one access aperture 72, or in other words a finger hole, for accessing and removing/reinstalling controller module 34.

A rack and pinion gear set 74 is connected between motor 28 and louvers 24. Rack and pinion gear set 74 includes at least one pinion gear 76 connected to a corresponding louver 24 and motor 28, and a rack gear 78 slidably connected to vent housing 22. Each of louvers 24 includes an axis of rotation 80 which is rotatably connected to housing 22. Pinion gears 76 are also rotatable about a corresponding axis of rotation 80. Motor 28 is mounted to housing 22 and the shaft of motor 28 is connected to at least one of louvers 24 such that when the motor shaft rotates, so rotates the louver 24 and corresponding pinion gear 76. This pinion gear 76 linearly actuates rack gear 78, which rotatably actuates the other pinion gear 76 and the other louver 24. Pinion gears 76 and rack gear 78 can be spur gears, although other types of gears are possible, and pinion gear 76 can be approximately partially circular, as shown, or other shapes. Although the embodiment shown in FIGS. 2-9 includes two louvers 24, the present invention can include a single louver, or more than two louvers, as required by the size and style of programmable vent 20. As shown particularly in FIGS. 5-6, manual override lever 82 is connected to rack gear 78, and protrudes through the front of aperture plate 26 so that a user can manually open or close louvers 24 by displacing lever 82 and therefore rack gear 78, which in turn rotates pinion gears 76 and corresponding louvers 24, and thereby manually overrides the programmed opening and/or closing of louvers 24.

Battery holder 84 holds, and provides the electrical terminals (not shown) for connection to the batteries, which batteries are electrically connected to, and provide electrical power for, controller 46 and the other electronic components on circuit board 42, motor 28, display 48, display backlight 56, a user input device 49 with pushbuttons 50, 52 and 54 (or other input devices) and, if needed, other electrical/electronic components as required.

The vent can have a decorative screw plug system (not shown) to hide mounting holes 86 in aperture plate or grill 26. Other elements can be used in place of motor 28, such as solenoid, to move louver 24 or another element that can block the flow of air through vent 20. The present invention can include a plastic grill 26 and a plastic housing 22, or other combinations of plastic, wood and metal, such as a plastic housing 22 and a metal aperture plate 26. A low battery audible alert function can be provided by an annunciator (not shown) and controller 46. Display 48 can be a liquid crystal display (LCD) or other display type, and further, can include a tilting feature or element (not shown) that allows a user to adjust the LCD, or other display device, to an angle that improves visibility and the ability to program the timing function.

Removable controller/timer module 34 can be removed from programmable vent 20, for reprogramming, repair, and/or replacement, or replacement of the batteries, without disturbing the mechanical configuration of programmable vent 20. Further, the circuit board 42 can have a backup battery (not shown) which can maintain the programmed settings during a main battery 58 change, for a limited time.

Vent 20 according to the present invention can have a snap-fit design where housing 22 has recesses in which corresponding tabs of aperture plate 26 can snap into, when assembling housing 22 to aperture plate 26. Housing 22 can be assembled to aperture plate 26 using other methods or materials such adhesives, potting, welding, slide locking tabs on housing 22 and aperture plate 26; and/or engaging sliding rails on housing 22 and aperture plate 26.

Programmable vent 20 includes a display 48 and a user input device 49, both connected to controller 38. User input device 49 has a set pushbutton 50, an hour pushbutton 52, and minute pushbutton 54 as shown, and/or other devices such as touch pads, switches, knobs and the like, or other devices as required by the functionality of programmable vent 20. Display 48 can include a current time indicator 88, a close time indicator 90, and a open time indicator 92, and/or other devices as required by the functionality of programmable vent 20. An example of how controller module 34 can be programmed to open and close louvers 24 is as follows. Vents 20 may typically be installed close to the floor, or high up on a wall, and/or have a piece of furniture in front of the vent, or otherwise be inconveniently located. Although not strictly required, as controller module 34 can be programmed while installed in vent 20, the first step may typically be removing controller module 34 from vent 20. The novel structure of the present invention has all of the moving parts which directly actuate louvers 24 remain in place in vent 20 when controller module 34 is removed from vent 20, which eliminates alignment issues, and associated breakage and wear and tear, when controller module 34 is removed/reinstalled. Press set pushbutton 50 once, and the legend “12H” or “24H” flashes in current time indicator 88 signifying twelve hour clock or twenty-four hour clock, respectively. Press hour pushbutton 52 to set timer in twelve hour clock format, or press minute pushbutton 54 to set timer in twenty-four hour clock format. Press set pushbutton 50 again and the hour and minute flashes in current time indicator 88. Press hour pushbutton 52 to set hours, and/or press minute pushbutton 54 to set minutes. When finished, press set pushbutton 50 and the day will be flashing. Press hour pushbutton 52 or minute pushbutton 54 to set the current day (M-Su). Two weekday (M-F) cycles and two weekend cycles (Sa-Su) are possible. To set the close and open time for the first weekday cycle, press and hold set pushbutton 50 for two-three seconds, and the timer in controller 34 enters the CLOSE time setting mode, and the close time flashes in close time indicator 90. Press hour pushbutton 52 to set hours, and/or press minute pushbutton 54 to set minutes. After setting the close time, press set pushbutton 50 to enter the OPEN time setting mode, and the open time flashes in open time indicator 92. Press hour pushbutton 52 to set hours, and/or press minute pushbutton 54 to set minutes. When finished, press set pushbutton 50 and a second weekday cycle is programmed similar to above, then a first weekend cycle, then a second weekend cycle. If any of these cycles are not desired then set pushbutton 50 twice after programming the previous cycle. After being programmed in this manner, the motor 28 is energized to open the louvers 24 at the OPEN time and energized to CLOSE the louvers at the close time. To keep the louvers 24 always closed, press and hold minute pushbutton 54 for two seconds. To hold the louvers open, press and hold hour pushbutton 52 for two seconds. On the next programmed open or close cycle, the module will resume its preprogrammed schedule. The time control module 34 program can be suspended by pressing and holding hour pushbutton 52 and minute pushbutton 54 at the same time for 2-3 seconds and the program will be suspended. To resume the program, press and hold hour pushbutton 52 and minute pushbutton 54 at the same time for 2-3 seconds and the programmed settings will be restored and the unit will function normally.

The programmable vent 20 can be in wireless communication with temperature sensor/transmitter 94, in which case, programmable vent 20 additionally includes an antenna 96 and receiver 98 for sensing, receiving and demodulating wireless signal 100 from temperature sensor/transmitter 94. Temperature sensor/transmitter 94 includes a temperature sensor such as a thermocouple or thermistor, or other temperature sensors. Additionally, temperature sensor/transmitter 94 includes an antenna and transmitter for broadcasting wireless signal 100. Wireless signal 100 is typically a wireless electromagnetic signal; however, wireless signal 100 can be other types of signals such as ultrasonic, or conducted electromagnetic signals through wires, fiber optics, coaxial cable, network cable, etc. Additionally, wireless signal 100 can include various spectrums of electromagnetic signals such as radio, microwave, millimeter wave, infrared and other electromagnetic spectrums. Wireless signal 100 includes temperature data relative to ambient temperature conditions in the near vicinity of temperature sensor/transmitter 94. Programmable vent 20 can use this data to temperature override the timed opening and closing of programmable vent 20. For example, if programmable vent 20 is not scheduled to open until 5:00 pm, but the room temperature falls below a setpoint override temperature of 50° F. for example, which is sensed by temperature sensor/transmitter 94, the louvers open allowing air to exit programmable vent 20. Alternatively, temperature sensor/transmitter 94 can be part of controller module 34 with the temperature input conducted to controller unit 38 via metal conductors, fiber optics, etc., in which case there is no need for the various antennas, and wireless transmitter/receiver pair.

Similarly, programmable vent 20 can include an infrared sensor/transmitter 102 providing an infrared input 100 to, and which is sensed by, controller module 34. Infrared sensor 102 can include an infrared sensor such as a pyroelectric detector, or other infrared sensors. Additionally, infrared sensor 102 includes an antenna and transmitter for broadcasting infrared input 100, which may have attributes similar to wireless signal 100. Wireless signal 100 includes infrared data relative to ambient infrared conditions in the near vicinity of infrared sensor 102. Wireless signal 100 can be emitted from temperature sensor/transmitter 94 and/or infrared sensor/transmitter 102 and can include the associated temperature and/or infrared input. Programmable vent 20 can use this data to override the timed opening and closing of programmable vent 20. For example, if programmable vent 20 is not scheduled to open until 5:00 pm, but infrared sensor 102 detects the presence of infrared energy indicative of a person walking into the room, controller module 34 can use this information to override the programmed event, open the louvers allowing air to exit programmable vent 20. As with temperature sensor/transmitter 94, infrared sensor 102 can be part of control module 34, providing a conducted input to the controller module.

In alternative embodiments, the present invention can include different types of louver options such as hinged louvers, sliding louvers, flip up louvers, or other types of louvers. For example, the programmable vent according to the present invention can include a sliding louver arrangement which includes a fixed aperture plate, a sliding louver and actuators in the form of push-pull solenoids which slide the sliding louver relative to the fixed aperture plate. Such a programmable vent can include a housing, a controller and circuit board with other components, a display, and a user input device, and other elements, as previously discussed.

The present invention can include a low battery icon which will show on display 48 when the batteries are running low, and controller module 34 can include an annunciator which produces a periodic audible signal, for example, every 40 seconds.

The present invention saves energy by closing vents in areas of a building where heating or cooling is not needed at that time. However, for proper airflow heating and/or cooling system 10 needs some of the total register vents open when the system is operating. For example, vent 20 can be installed in multiple locations in a home, but a user must count the total vents in the building/home and program them so that a minimum percentage, for example 60%, of all vents in the home are open when the heating or cooling system 10 is running. This percentage can vary depending on system 10 characteristics and the particular locations of the programmed vents. Consequently, a system may need approximately between 20% and 90% of the vents open at any given time, if system 10 is running.

While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.

Claims

1. A programmable vent for a duct used with a building environmental air temperature control system, said programmable vent comprising: a vent housing having a front face with an inset, said vent housing configured to allow air flow from the duct;at least one louver movably connected to said vent housing;an actuator connected to said at least one louver;a controller module removably attached to said vent housing and positioned in said inset, said controller module connected to said actuator when positioned in said inset.

2. The programmable vent of claim 1, wherein said actuator includes an electric motor, said controller module being electrically connected to said electric motor when positioned in said inset.

3. The programmable vent of claim 1, wherein said controller module includes a circuit board with motor controls connected to said electric motor, further including a display, a user input device, batteries and associated wiring all electrically connected to said circuit board.

4. A programmable vent for a duct used with a building environmental air temperature control system, said programmable vent comprising: a vent housing configured to allow air flow from the duct;at least one louver movably connected to said vent housing;an electric motor connected to said at least one louver;a first plurality of electrical terminals connected to said electric motor and fixedly connected to said vent housing; anda controller module removably attached to said vent housing, said controller module including a controller housing and a controller unit within said controller housing, said controller unit including a second plurality of electrical terminals resiliently contacting said first plurality of electrical terminals.

5. The programmable vent of claim 4, wherein said controller unit includes a circuit board with motor controls connected to said second plurality of terminals.

6. The programmable vent of claim 5, wherein said controller module further includes a display, a user input device, batteries and associated wiring all electrically connected to said circuit board.

7. The programmable vent of claim 4, wherein said controller housing is in a snap fit arrangement with said vent housing.

8. The programmable vent of claim 7, wherein said snap fit arrangement comprises at least one resilient ramped projection connected to said controller housing, and at least one detent in said vent housing, said at least one resilient ramped projection insertable in a corresponding said at least one detent when said controller housing is in said snap fit arrangement with said vent housing.

9. The programmable vent of claim 8, wherein said vent housing further includes a frame in which said controller module is inserted, said frame includes at least one access aperture for accessing said controller module.

10. The programmable vent of claim 4, further including a rack and pinion gear set connected between said electric motor and said at least one louver.

11. The programmable vent of claim 10, wherein said rack and pinion gear set includes at least one pinion gear connected to a corresponding said louver and said motor, and a rack gear slidably connected to said vent housing.

12. The programmable vent of claim 4, further including a temperature sensor providing a temperature input to said controller module, said controller module sensing said temperature input.

13. The programmable vent of claim 12, wherein said temperature sensor is in wireless communication with said controller module.

14. The programmable vent of claim 4, further including an infrared sensor providing an infrared input to said controller module, said controller module sensing said infrared input.

15. The programmable vent of claim 14, wherein said infrared sensor is in wireless communication with said controller module.

16. A building environmental air temperature control system, comprising: at least one of a heating system and a cooling system;at least one duct connected to at least one of said heating system and said cooling system;a programmable vent connected to a corresponding said at least one duct, said programmable vent including: a vent housing through which air flows from the duct;at least one louver movably connected to said vent housing;an electric motor connected to said at least one louver;a first plurality of electrical terminals connected to said electric motor and fixedly connected to said vent housing; anda controller module removably attached to said vent housing, said controller module including a controller housing and a controller unit within said controller housing, said controller unit including a second plurality of electrical terminals resiliently contacting said first plurality of electrical terminals.

17. The building environmental air temperature control system of claim 16, wherein said controller unit includes a circuit board with motor controls connected to said second plurality of terminals.

18. The building environmental air temperature control system of claim 17, wherein said controller module further includes a display, a user input device, batteries and associated wiring all connected to said circuit board.

19. The building environmental air temperature control system of claim 16, wherein said controller housing is in a snap fit arrangement with said vent housing.

20. The building environmental air temperature control system of claim 19, wherein said snap fit arrangement comprises at least one resilient ramped projection connected to said controller housing, and at least one detent in said vent housing, said at least one resilient ramped projection insertable in a corresponding said at least one detent when said controller housing is in said snap fit arrangement with said vent housing.

21. The building environmental air temperature control system of claim 20, wherein said vent housing further includes a frame in which said controller module is inserted, said frame includes at least one access aperture for accessing said controller module.

22. The building environmental air temperature control system of claim 16, further including a rack and pinion gear set connected between said electric motor and said at least one louver.

23. The building environmental air temperature control system of claim 22, wherein said rack and pinion gear set includes at least one pinion gear connected to a corresponding said louver and said motor, and a rack gear slidably connected to said vent housing.

24. The building environmental air temperature control system of claim 16, further including a temperature sensor providing a temperature input to said controller module, said controller module sensing said temperature input.

25. The building environmental air temperature control system of claim 24, wherein said temperature sensor is in wireless communication with said controller module.

26. The building environmental air temperature control system of claim 16, further including an infrared sensor providing an infrared input to said controller module, said controller module sensing said infrared input.

27. The building environmental air temperature control system of claim 26, wherein said infrared sensor is in wireless communication with said controller module.

28. A method of controlling air flow within a building environmental air temperature control system, comprising the steps of: providing a programmable vent including housing having a front face with an inset, said vent housing configured to allow air flow from the duct, at least one louver movably connected to said vent housing, an actuator connected to said at least one louver, a controller module removably attached to said vent housing and positioned in said inset, said controller module connected to said actuator when positioned in said inset;removing said controller module from said programmable vent;programming said controller module to open and close said at least one louver;reinstalling said controller module into said programmable vent; andselectively controlling an air flow exiting said duct using said programmable vent.

29. A programmable vent for a duct used with a building environmental air temperature control system, said programmable vent comprising: a vent housinga fixed aperture plate connected to the vent housing, the fixed aperture plate including a plurality of apertures configured for accepting air flow through the vent housing from the duct; andat least one movable aperture plate connected to the vent housing and slidable relative to the fixed aperture plate between an open position which substantially allows the air flow and a closed position which substantially restricts the air flow.

30. The programmable vent of claim 29, wherein at least one said movable aperture plate is horizontally slidable relative to the fixed aperture plate.

31. The programmable vent of claim 29, further including an actuator connected to at least one movable aperture plate.

32. The programmable vent of claim 31, further including a controller module attached to the vent housing the controller module for controlling the actuator.

33. The programmable vent of claim 31, further including a rack and pinion gear set connected between the actuator and at least one said movable aperture plate.

34. A programmable vent for a duct used with a building environmental air temperature control system, said programmable vent comprising: a vent housing;a fixed ventilation element connected to the vent housing;at least one movable ventilation element connected to the vent housing and movable relative to the fixed ventilation element; anda rack and pinion gear set connected between the at least one movable ventilation element and the vent housing.

35. The programmable vent of claim 34, further including an actuator connected to at least one ventilation element.

36. The programmable vent of claim 35, wherein the rack and pinion gear set includes a rack gear and a pinion gear, the rack gear being connected to at least one of the actuator and the vent housing, the pinion gear being connected to the other of the actuator and the vent housing.