US20120302152A1 - Universal Air Pattern Controller for a Diffuser - Google Patents

Universal Air Pattern Controller for a Diffuser Download PDF

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Publication number
US20120302152A1
US20120302152A1 US13/117,753 US201113117753A US2012302152A1 US 20120302152 A1 US20120302152 A1 US 20120302152A1 US 201113117753 A US201113117753 A US 201113117753A US 2012302152 A1 US2012302152 A1 US 2012302152A1
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United States
Prior art keywords
air pattern
universal air
slot diffuser
diffuser
slot
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US13/117,753
Inventor
Alfred Theodor Dyck
Jaroslaw Nowak
Adam Pfeiffer
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EH Price Ltd
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Individual
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Priority to US13/117,753 priority Critical patent/US20120302152A1/en
Assigned to E.H. PRICE, LTD. reassignment E.H. PRICE, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DYCK, ALF, NOWAK, JAROSLAW, PFEIFFER, ADAM
Publication of US20120302152A1 publication Critical patent/US20120302152A1/en
Abandoned legal-status Critical Current

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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24FAIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F13/00Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening
    • F24F13/08Air-flow control members, e.g. louvres, grilles, flaps or guide plates
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24FAIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F13/00Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening
    • F24F13/02Ducting arrangements
    • F24F13/06Outlets for directing or distributing air into rooms or spaces, e.g. ceiling air diffuser
    • F24F13/072Outlets for directing or distributing air into rooms or spaces, e.g. ceiling air diffuser of elongated shape, e.g. between ceiling panels
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24FAIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F13/00Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening
    • F24F13/02Ducting arrangements
    • F24F13/06Outlets for directing or distributing air into rooms or spaces, e.g. ceiling air diffuser
    • F24F13/075Outlets for directing or distributing air into rooms or spaces, e.g. ceiling air diffuser having parallel rods or lamellae directing the outflow, e.g. the rods or lamellae being individually adjustable

Definitions

  • the present invention is directed toward air pattern controllers for controlling the direction and velocity of air flow from a diffuser into a room.
  • the present invention is directed toward a universal air pattern controller for use in air slot diffusers of any shape, including curved applications.
  • Air distribution devices also referred to as diffusers
  • Slot diffusers have elongate, narrow slots, each of which is open across its full width and enclosed by a frame.
  • an air supply system In order to successfully supply air into an occupied space, an air supply system must deliver air from suitable locations, in appropriate volumes, in proper directions, and at correct velocities. Except in very high-ceilinged spaces, the proper direction for air emitted from the diffuser is in a tight, horizontal pattern closely hugging the ceiling of the occupied space.
  • the primary means for effecting such a horizontal pattern in a slot diffuser is through an air pattern controller within the slot diffuser approximately at or adjacent to the plane of the ceiling undersurface, which deflects the air across the ceiling.
  • Slot diffusers are used in many different environments for introducing heated or cooled air flow into an occupied space, and are frequently used to satisfy architectural concepts that require continuous length applications without compromising air distribution performance.
  • Conventional slot diffusers are generally either linear or curved, though the configurations can present other specialized shapes.
  • Air pattern controllers contribute to the performance of a slot diffuser, and preferably provide a range of air pattern adjustments.
  • Ice-tong air pattern controllers are assembled extrusions typically constructed with two separate curved vanes pivotally mounted at a top end on a vertical member such that each of the respective vanes pivots in an opposite direction away from the vertical member.
  • the hinge point at which the two vanes are connected permits a user to direct two points on a bottom or working end of the vanes to create a desired angle, or to contact a side wall.
  • the positioning of the vanes in either opposite directions or the same direction dictates the direction of the air flow from the corresponding air slot.
  • pivoting one or both vanes such that the working end of the vane contacts a side wall can completely obstruct the flow of air from the air slot.
  • this conventional type of air pattern controller can be seen in the PTBA series plenum linear slot diffusers made by the Krueger Manufacturing Company, and in the ML series linear slot diffusers made by The Titus Company. Ice-tong pattern controllers allow for simple adjustment in the direction and volume of the air flow
  • Ice-tong pattern controllers can be adjusted to alter the direction and velocity of air flow, but such adjustments require the manual placement and use of extra positioning parts to selectively “hang” the ice-tong pattern controller elements in a desired manner. The installation of these extra positioning parts increases the necessary cost, materials, and assembly time. This is particularly problematic when adjustability is not a requirement for the application.
  • Blade pattern controllers are fixedly mounted to a slot diffuser side wall at a mounting end, and direct air around a working end and out of the corresponding air slot in a fixed direction.
  • These pattern controllers are typically L-shaped extrusions, with a short arm connected at a vertex to a long arm. The short arm extends from the mounting end, and is permanently fixed to the side wall, typically by spot welding, such that the long arm extends substantially perpendicularly into the air slot space to direct the flow of air as it exits the slot diffuser.
  • L-shaped blade pattern controllers can be modified for use in conjunction with a curved slot diffuser. This curvature, however, often results in erratic throw patterns.
  • blade pattern controllers generally allow for easy installation with few necessary parts in fixed applications
  • use of a blade pattern controller in a curved application as described above requires laborious, time-consuming, and skilled constructing, notching, positioning, and mounting.
  • the L-shaped blade pattern controller profiles tend to twist when manufactured, and when installed in curved slot diffusers because the neutral axis does not lie in a plane perpendicular to the direction of curvature.
  • constructing a slot diffuser with an L-shaped blade pattern controller requires a fourth surface to counteract twisting, which must be tuned manually with high precision.
  • L-shaped blade pattern controllers do not perform well when compared with conventional air pattern controllers, including the ice-tong pattern controller.
  • L-shaped blade pattern controllers used in conjunction with slot diffusers typically suffer from high noise output and an unacceptable pressure drop when air is directed over the knife or square working edge. Often, a complete loss of pattern control results.
  • the gap between the room-side of the pattern controller and the frame flange also contributes to the pressure drop because a Coand ⁇ hacek over (a) ⁇ effect is not generated until the fluid stream leaves the diffuser.
  • Air pattern controllers are not ideally suited for use in slot diffusers with curves or other shapes.
  • Air pattern controllers that are capable of being used in curved or shaped slot diffusers typically suffer from poor performance, and must be significantly modified such that the construction, shape, and/or mounting of each air pattern controller is unique to the specific application. What is needed is an air pattern controller that can easily be mounted in a desirable position within a linear, curved, angled, or shaped slot diffuser. Further, a single air pattern controller design is needed for universal use in all available slot diffuser shapes without modification of the controller. Still further, an air pattern controller is needed that can be mounted within a slot diffuser using a small amount of time and parts. It is to these needs and others that the present invention is directed.
  • a universal air pattern controller in accordance with an embodiment of the present invention comprises at least one elongate, tubular element mounted within a slot diffuser frame.
  • the substantially smooth and curved surface of the universal air pattern controller provides superior performance when compared with conventional air pattern controllers, especially when used in curved or uniquely-shaped slot diffusers.
  • the tubular profile of the universal air pattern controller allows for quick and easy mounting within a slot diffuser of any shape without further modification.
  • the universal air pattern controller is used in conjunction with a two-slot air diffuser.
  • the slot diffuser comprises two side frames mounted on opposing sides of a center frame.
  • a linear bar, H-bar, or other conventional spacer joins the side frames and the center frame, and provides structural support to the slot diffuser.
  • the side frames each have a flange extending from a bottom edge of the side frame toward the center frame.
  • the center frame likewise has two flanges extending from its bottom edge toward each corresponding opposing side frame.
  • the side and center frames can be slidably mounted at their top edges to the H-bar on a track having an upper and lower lip, or can be fixedly mounted with screws, bolts, welding, or the like, or can be snapped into place into a reciprocally mating profile.
  • a tubular universal air pattern controller is mounted in each of two air slots and abuts both the side frame flange and the lower lip of the side frame track such that both universal air pattern controllers are mounted distal to the center frame.
  • the universal air pattern controllers can be mounted such that each abuts the center frame flange and the lower lip of the center frame track.
  • both universal air pattern controllers are mounted proximal to the center frame. Also alternatively, any combination of these positions can be employed to achieve flow patterns in opposite directions from selected air slots.
  • the universal air pattern controllers can be held into place with one or more spring clips.
  • the spring clips can have a profile adapted at a first end to mate with the lower lip of a side frame track or center frame track, and at a second end to abut and firmly hold the universal air pattern controller into place.
  • the spring clips of this exemplary embodiment are removably attached, and can be applied at regular or desired intervals in order to secure the universal air pattern controller within the slot diffuser. In other embodiments, the spring clip is fixedly attached.
  • the universal air pattern controller of the present invention mounted within a slot diffuser induces a maximized Coand ⁇ hacek over (a) ⁇ effect when the curved surface of the tubular universal air pattern controller is applied into an air stream. This is because the working surface of the of the universal air pattern controller transitions seamlessly, or at least provides a substantially smooth or curved transition, into the interior frame surface.
  • the Coand ⁇ hacek over (a) ⁇ effect is created at a point before the fluid leaves the slot diffuser, which causes the air to flow in a tight path across the ceiling of an occupied space.
  • the universal air pattern controllers can be mounted in a fixed position against the side frames and side frame flanges or the center frame and the center frame flanges of the diffuser with conventional mechanical fasteners to hold them in position.
  • the universal air pattern controllers can be mounted in both curved and straight slot diffusers with one or more spring clips without the requirement of additional mounting parts.
  • the universal air pattern controllers can be applied in pattern-adjustable slot diffusers by implementing only pattern controller translation because the universal air pattern controller itself is not required to rotate, even as it translates along a curved path.
  • the universal air pattern controller is not strictly required to be unitarily tubular or perfectly circular in accordance with the present invention, this embodiment of the universal air pattern controller is preferred.
  • the universal air pattern controller can easily be manufactured using a 3-point roll former or similar equipment without significant deformation or twisting because of the orientation of the neutral axis the even surface relative to the roll-former.
  • FIG. 1 is a front perspective view of two universal air pattern controllers positioned in a linear dual slot diffuser with an end cap removed in accordance with the present invention
  • FIG. 2 a is a front elevation view of two universal air pattern controllers positioned in a linear dual slot diffuser with an end cap removed, showing a distal positioning of the universal air pattern controllers and a horizontal direction of airflow.
  • FIG. 2 b is a bottom perspective view of a curved dual slot diffuser showing a distal positioning of the universal air pattern controllers.
  • FIG. 3 is a front cross sectional view of a slot diffuser with a single air slot and a single universal air pattern controller with a fixed mount in an exterior lower position.
  • FIG. 4 is a front cross sectional view of an embodiment of the universal air pattern controller in an adjustable implementation, demonstrating positioning of the universal air pattern controller in a first exterior lower position and the transition path to a second an interior lower position, respectively.
  • FIG. 5 is a front cross sectional view of one half of the slot diffuser of FIG. 1 showing the universal air pattern controller mounted within the slot diffuser with a spring clip.
  • FIG. 6 is an exploded perspective view of the curved dual slot diffuser of FIG. 2 b.
  • FIG. 7 is a perspective view the curved dual slot diffuser of FIG. 2 b , assembled, showing a distal positioning of the universal air pattern controllers with spring clips.
  • FIGS. 1 through 7 Illustrative embodiments of a universal air pattern controller 15 for controlling the flow of air from a slot diffuser 10 into an occupied space in accordance with the present invention are shown in FIGS. 1 through 7 .
  • an exemplary embodiment of a universal air pattern controller 15 is used in conjunction with a two-slot linear air diffuser 10 .
  • the slot diffuser 10 comprises two opposing parallel side frames 20 mounted on opposing sides of a center frame 25 .
  • the first and second side frames 20 and the center frame 25 include flanges 30 in edgewise opposition to each other to define an elongate discharge air slot 45 therebetween ( FIG. 3 ). It is preferable that the side frames 20 and center frame 25 be constructed from aluminum extrusions.
  • the side frames 20 each have a single narrow longitudinal flange 30 formed as an integral extrusion and extending inwardly toward the air slot 45 at a bottom edge.
  • side frames 20 further comprise a track 40 having an upper lip 40 a at a top edge and a lower lip 40 b between the top edge and the flange 30 , which define a recessed area 41 .
  • the track 40 faces inwardly toward the air slot 45 , and can be formed integrally with the side frame 20 extrusion, or can be mechanically attached thereto.
  • the center frame 25 is an intermediate wall within the diffuser having a “T-shaped” cross-section, and forms a means for dividing the space between the opposing side frames 20 and a support for the structure.
  • the center frame 25 comprises two narrow longitudinal flanges 30 formed as an integral extrusion, each extending in opposite directions toward a flange 30 of a corresponding side frame 20 . Both flanges 30 of the center frame 25 join together to form a continuous surface and create the “T-shape” of the extrusion.
  • the flanges 30 are intended to be mounted in overlapping fashion with adjacent ceiling tiles (not shown) in the ceiling of the occupied space in which the slot diffuser is to be mounted.
  • the center frame 25 also optionally comprises two tracks 40 , each having an upper lip 40 a at a top edge and a lower lip 40 b between the top edge and the flanges 30 of the center frame 25 , which define recessed areas 43 .
  • Each track 40 faces a side frame 20 , and can be formed integrally with the center frame 25 extrusion, or can be mechanically attached thereto.
  • the center frame 25 can be mounted to each side frame 20 via a spacer, for example, a dual-sided horizontal H-bar 35 .
  • the H-bar 35 has portions on each side capable of mating with a track 40 on either or both of a side frame 20 or a center frame 25 such that the H-bar 35 is adapted to slidably connect to the side frames 20 and the center frame 25 .
  • the center frame 25 is attached to a side frame 20 by slidably mounting the correspondingly-shaped portion on the side of the H-bar 35 into a recessed area 47 ( FIG. 5 ) of the track 40 defined by the upper lip 40 a and lower lip 40 b of the first side frame 20 .
  • the H-bar 35 is then slidably mounted in a similar manner to the track 40 on the center frame 25 facing the corresponding first side frame 20 . This process is then repeated on the other side to attach the second side frame 20 to the center frame 25 .
  • a complete slot diffuser 10 will typically have a spacer such as an H-bar 35 at each end of the diffuser, and can have one or more H-bars 35 spaced therebetween as needed to provide support for the slot diffuser 10 and to keep its component parts in place.
  • the H-bar 35 also functions to provide structural support to the slot diffuser 10 .
  • the H-bar 35 is preferably constructed from a metal material to maintain its rigidity.
  • a linear slot diffuser 10 comprises only two side frames 20 connected to a single H-bar 35 without any center frame 25 .
  • the flanges 30 of the side frames 20 define a single air slot 45 .
  • the linear slot diffuser 10 comprises multiple side frames 20 and multiple center frames 25 connected by a corresponding number of H-bars 35 . This embodiment would typically define two air slots 45 per pair of side frames 20 .
  • FIG. 5 discloses one half of a linear slot diffuser 10 with a side frame 20 and a center frame 25 .
  • end caps can be applied at each end of the diffuser to enhance architectural appeal.
  • the universal air pattern controller 15 in accordance with an embodiment of the present invention comprises one or more elongate, tubular elements 15 mounted within each air slot 45 of the slot diffuser 10 .
  • the universal air pattern controller 15 abuts both the flange 30 and the lower lip 40 b of the track 40 of the side frame 20 .
  • the universal air pattern controller 15 is a single, unitary and enclosed tube with a circular cross section extending substantially the length of the slot diffuser 10 .
  • two universal air pattern controllers 15 are mounted distal to the center frame 25 .
  • the pair of universal air pattern controllers 15 can be mounted such that each abuts one of the flanges 30 of the center frame 25 and one of the lower lips 40 b of the track 40 of the center frame 25 .
  • both universal air pattern controllers 15 are mounted adjacent to the center frame 25 .
  • any combination of mounting positions can be employed to achieve the desired air flow into the occupied space.
  • at least one universal air pattern controller 15 is mounted on either side frame 20 between its corresponding flange 30 and lower lip 40 b in a first position 50 a (shown in FIG. 4 ) or a second position 50 b depending on the desired direction of air flow.
  • the one or more universal air pattern controllers 15 can be fixedly or removably attached and held into place with one or more spring clips 55 .
  • the spring clip 55 is a thin, flexible piece of wire or other similar molded or shaped hardware suitable for supplying supporting frictional force to urge the universal air pattern controller 15 into engagement with the side frame 20 or center frame 25 and hold it securely into place.
  • the spring clip 55 has a profile adapted at a first end 65 to mate with the lower lip 40 b of the track of the side frame 20 or with the lower lip 40 b of the track of the center frame 25 , and is adapted at a second end 60 to abut and firmly hold the universal air pattern controller 15 into place.
  • the spring clips 55 in this exemplary embodiment are applied at regular or desired intervals in order to secure the universal air pattern controller 15 in place within the air slot 45 .
  • the spring clips 55 are preferably removably attached to the side frame 20 or center frame 25 of the slot diffuser 10 and the universal air pattern controller 15 .
  • the spring clips 55 or the universal air pattern controller 15 are fixedly mounted to the side frames 20 or the center frame 25 with a mechanical fastener, such as a nail, screw, or bolt, by welding, or with an adhesive.
  • the universal air pattern controllers 15 are oriented in a position distal to the center frame 25 . This orientation directs air flow downward through the air slot 45 and horizontally in a flow direction 70 away from the center frame 25 along the ceiling of an occupied space. Changing the mounting orientation of the universal air pattern controllers 15 to the opposite side of the air slot 45 will serve to direct the air flow in an opposite flow direction 70 .
  • the universal air pattern controllers 15 are mountable in a fixed or a removable position either upon installation or during fabrication by manual manipulation and fixation with one or more spring clips 55 as described herein to provide for different flow characteristics such as volume control and directional control.
  • FIGS. 2B , 6 , and 7 an alternative embodiment of the slot diffuser 110 with a universal air pattern controller 115 in accordance with the present invention is shown.
  • the tubular universal air pattern controllers 115 are mounted within the curved slot diffuser 110 .
  • At least a portion of the profile of the curved slot diffuser 110 and at least a portion of each air slot 145 is arcuate.
  • Extruded side frames 120 and a center frame 125 are likewise curved, and can be slidably joined at tracks 140 having an upper and lower lip, 140 a and 140 b respectively, by a spacer such as an H-bar 135 in the manner described above.
  • Flanges 130 are preferably unitarily extruded and curved, and define the curved air slot 145 .
  • the universal air pattern controllers 115 are mounted along and shaped during fabrication to correspond to the curved profile of the curved slot diffuser 110 and are held in place by one or more spring clips 155 with a first end 165 adapted to abut the universal air pattern controller 115 , and a second end 160 adapted to mate with the lower lip 140 a.
  • the universal air pattern controllers 15 and 115 in accordance with the present invention have a single design for straight, curved, and shaped slot diffusers 10 and 110 , that is easy to manufacture and install and provides superior air pattern control to linear, concave or convex curved, circular, ovular, triangular, and hexagonal applications, for example, without the need to re-engineer and fabricate the working components within the slot diffusers 10 and 110 .
  • the side frames 20 and the center frame 25 of the slot diffuser 10 used in conjunction with the universal air pattern controller 15 are of a solid extruded aluminum construction.
  • the side frames 20 and the center frame 25 can be constructed of specialized materials for architectural or functional purposes, like stainless steel, brass, bronze, or other materials that would traditionally limit conventional fabrication of the slot diffusers 10 and make the mounting of the universal air pattern controller 15 particularly difficult.
  • the universal air pattern controller 15 is preferably constructed of extruded aluminum. Although building codes and other regulations may restrict the materials that can be used, in certain application, in application where codes and regulations do not so limit the materials to be used, the universal air pattern controller 15 can be constructed from any durable material capable of being bent or shaped to correspond to the contours of the slot diffuser 10 . Alternatively, the universal air pattern controller 15 can be constructed from a flexible material such as rubber, plastic, thermoplastic, polypropylene, polyurethane, polyethylene, polyvinyl chloride and the like. The universal air pattern controller 15 can also be constructed of corrugated metal or plastic, braided wire, interlocking metal, multiple flexible layers of material, or incorporate fibrous reinforcement like braided nylon. The universal pattern controller 15 and can be extruded, injection molded, or formed from other methods known in the art, and can be shaped during fabrication, or at any time prior to installation.
  • the universal air pattern controller 15 of the slot diffuser 10 induces a maximized Coand ⁇ hacek over (a) ⁇ effect at a point just before the fluid leaves the slot diffuser 10 , it is capable of creating tight, ceiling-hugging horizontal air patterns as well as vertical air patterns.
  • the universal air pattern controller 15 can easily be manufactured and shaped using standard equipment like a 3-point roll former without significant deformation or twisting. Though a circular cross section is preferred, the universal air pattern controller 15 can have a cross section that is oval, ovoid, or other substantially rounded shapes.
  • the surface of the universal air pattern controller 15 is preferably smooth, but can alternatively incorporate textures that do not substantially interfere with the air flow across the surface.
  • the universal air pattern controller 15 need not be completely enclosed to form a true tube, but rather, must be at least substantially enclosed such that the working surface of the universal air pattern controller 15 is continuous.

Abstract

A universal air pattern controller for use in conjunction with a slot diffuser comprises one or more tubular, elongate universal air pattern controllers mounted with a spring clip to a diffuser frame. The diffuser frame comprises two side frames mounted on opposing sides of a center frame by a spacer, each of the side frames and center frame having flanges which define an elongate slot from which air exits the diffuser. The universal air pattern controller is suitable, without modification or customization, for use in both conventional and linear slot diffuser applications and in non-traditional curved, angled, or specially-shaped diffuser applications.

Description

    BACKGROUND OF THE INVENTION
  • 1. Technical Field
  • The present invention is directed toward air pattern controllers for controlling the direction and velocity of air flow from a diffuser into a room. In particular, the present invention is directed toward a universal air pattern controller for use in air slot diffusers of any shape, including curved applications.
  • 2. Prior Art
  • Air distribution devices, also referred to as diffusers, are typically set into a ceiling or other walls in a room and receive conditioned air along their length from a supply duct. Slot diffusers have elongate, narrow slots, each of which is open across its full width and enclosed by a frame. In order to successfully supply air into an occupied space, an air supply system must deliver air from suitable locations, in appropriate volumes, in proper directions, and at correct velocities. Except in very high-ceilinged spaces, the proper direction for air emitted from the diffuser is in a tight, horizontal pattern closely hugging the ceiling of the occupied space. The primary means for effecting such a horizontal pattern in a slot diffuser is through an air pattern controller within the slot diffuser approximately at or adjacent to the plane of the ceiling undersurface, which deflects the air across the ceiling.
  • Slot diffusers are used in many different environments for introducing heated or cooled air flow into an occupied space, and are frequently used to satisfy architectural concepts that require continuous length applications without compromising air distribution performance. Conventional slot diffusers are generally either linear or curved, though the configurations can present other specialized shapes.
  • In some applications, it is desirable to provide a high velocity air stream from one or more air slots that flows generally perpendicularly into the room relative to the face of the diffuser. In other applications, it is desirable to direct one or more air streams in other directions relative to the face of the diffuser into the room. Air pattern controllers contribute to the performance of a slot diffuser, and preferably provide a range of air pattern adjustments.
  • One conventional air pattern controller typically used in conjunction with a linear slot diffuser is the axial adjustable, or “ice-tong,” pattern controller. Ice-tong air pattern controllers are assembled extrusions typically constructed with two separate curved vanes pivotally mounted at a top end on a vertical member such that each of the respective vanes pivots in an opposite direction away from the vertical member. The hinge point at which the two vanes are connected permits a user to direct two points on a bottom or working end of the vanes to create a desired angle, or to contact a side wall. The positioning of the vanes in either opposite directions or the same direction dictates the direction of the air flow from the corresponding air slot. Alternatively, pivoting one or both vanes such that the working end of the vane contacts a side wall can completely obstruct the flow of air from the air slot. Examples of this conventional type of air pattern controller can be seen in the PTBA series plenum linear slot diffusers made by the Krueger Manufacturing Company, and in the ML series linear slot diffusers made by The Titus Company. Ice-tong pattern controllers allow for simple adjustment in the direction and volume of the air flow
  • Although it is standard practice in the HVAC industry to provide pattern-adjustable linear slot diffusers that utilize ice-tong pattern controllers, these controllers are not suitable for curved applications. The pivot points of the ice-tong pattern controller, which are necessary for its operation, cannot be aligned properly if an arc is present in profile of the slot diffuser. Additionally, an ice-tong pattern controller cannot be rotated to accommodate a curved diffuser profile because the curvature of the ice-tong pattern controller cannot maintain alignment within the diffuser frame. Ice-tong pattern controllers can be adjusted to alter the direction and velocity of air flow, but such adjustments require the manual placement and use of extra positioning parts to selectively “hang” the ice-tong pattern controller elements in a desired manner. The installation of these extra positioning parts increases the necessary cost, materials, and assembly time. This is particularly problematic when adjustability is not a requirement for the application.
  • Other conventional air pattern controllers used in conjunction with slot diffusers include blade-style pattern controllers. Blade pattern controllers are fixedly mounted to a slot diffuser side wall at a mounting end, and direct air around a working end and out of the corresponding air slot in a fixed direction. These pattern controllers are typically L-shaped extrusions, with a short arm connected at a vertex to a long arm. The short arm extends from the mounting end, and is permanently fixed to the side wall, typically by spot welding, such that the long arm extends substantially perpendicularly into the air slot space to direct the flow of air as it exits the slot diffuser. L-shaped blade pattern controllers can be modified for use in conjunction with a curved slot diffuser. This curvature, however, often results in erratic throw patterns.
  • Though blade pattern controllers generally allow for easy installation with few necessary parts in fixed applications, use of a blade pattern controller in a curved application as described above requires laborious, time-consuming, and skilled constructing, notching, positioning, and mounting. Further, the L-shaped blade pattern controller profiles tend to twist when manufactured, and when installed in curved slot diffusers because the neutral axis does not lie in a plane perpendicular to the direction of curvature. Thus, constructing a slot diffuser with an L-shaped blade pattern controller requires a fourth surface to counteract twisting, which must be tuned manually with high precision.
  • Testing has shown that L-shaped blade pattern controllers do not perform well when compared with conventional air pattern controllers, including the ice-tong pattern controller. L-shaped blade pattern controllers used in conjunction with slot diffusers typically suffer from high noise output and an unacceptable pressure drop when air is directed over the knife or square working edge. Often, a complete loss of pattern control results. Further, the gap between the room-side of the pattern controller and the frame flange also contributes to the pressure drop because a Coand{hacek over (a)} effect is not generated until the fluid stream leaves the diffuser.
  • Conventional air pattern controllers, thus, are not ideally suited for use in slot diffusers with curves or other shapes. Air pattern controllers that are capable of being used in curved or shaped slot diffusers typically suffer from poor performance, and must be significantly modified such that the construction, shape, and/or mounting of each air pattern controller is unique to the specific application. What is needed is an air pattern controller that can easily be mounted in a desirable position within a linear, curved, angled, or shaped slot diffuser. Further, a single air pattern controller design is needed for universal use in all available slot diffuser shapes without modification of the controller. Still further, an air pattern controller is needed that can be mounted within a slot diffuser using a small amount of time and parts. It is to these needs and others that the present invention is directed.
  • BRIEF SUMMARY OF INVENTION
  • A universal air pattern controller in accordance with an embodiment of the present invention comprises at least one elongate, tubular element mounted within a slot diffuser frame. The substantially smooth and curved surface of the universal air pattern controller provides superior performance when compared with conventional air pattern controllers, especially when used in curved or uniquely-shaped slot diffusers. The tubular profile of the universal air pattern controller allows for quick and easy mounting within a slot diffuser of any shape without further modification.
  • In an exemplary embodiment, the universal air pattern controller is used in conjunction with a two-slot air diffuser. The slot diffuser comprises two side frames mounted on opposing sides of a center frame. A linear bar, H-bar, or other conventional spacer joins the side frames and the center frame, and provides structural support to the slot diffuser. The side frames each have a flange extending from a bottom edge of the side frame toward the center frame. The center frame likewise has two flanges extending from its bottom edge toward each corresponding opposing side frame. The side and center frames can be slidably mounted at their top edges to the H-bar on a track having an upper and lower lip, or can be fixedly mounted with screws, bolts, welding, or the like, or can be snapped into place into a reciprocally mating profile.
  • In one embodiment, a tubular universal air pattern controller is mounted in each of two air slots and abuts both the side frame flange and the lower lip of the side frame track such that both universal air pattern controllers are mounted distal to the center frame. Alternatively, the universal air pattern controllers can be mounted such that each abuts the center frame flange and the lower lip of the center frame track. In this embodiment, both universal air pattern controllers are mounted proximal to the center frame. Also alternatively, any combination of these positions can be employed to achieve flow patterns in opposite directions from selected air slots.
  • Once positioned, the universal air pattern controllers can be held into place with one or more spring clips. In one embodiment, the spring clips can have a profile adapted at a first end to mate with the lower lip of a side frame track or center frame track, and at a second end to abut and firmly hold the universal air pattern controller into place. The spring clips of this exemplary embodiment are removably attached, and can be applied at regular or desired intervals in order to secure the universal air pattern controller within the slot diffuser. In other embodiments, the spring clip is fixedly attached.
  • The universal air pattern controller of the present invention mounted within a slot diffuser induces a maximized Coand{hacek over (a)} effect when the curved surface of the tubular universal air pattern controller is applied into an air stream. This is because the working surface of the of the universal air pattern controller transitions seamlessly, or at least provides a substantially smooth or curved transition, into the interior frame surface. Thus, the Coand{hacek over (a)} effect is created at a point before the fluid leaves the slot diffuser, which causes the air to flow in a tight path across the ceiling of an occupied space.
  • The universal air pattern controllers can be mounted in a fixed position against the side frames and side frame flanges or the center frame and the center frame flanges of the diffuser with conventional mechanical fasteners to hold them in position. The universal air pattern controllers can be mounted in both curved and straight slot diffusers with one or more spring clips without the requirement of additional mounting parts. In an alternative embodiment, the universal air pattern controllers can be applied in pattern-adjustable slot diffusers by implementing only pattern controller translation because the universal air pattern controller itself is not required to rotate, even as it translates along a curved path.
  • Although the universal air pattern controller is not strictly required to be unitarily tubular or perfectly circular in accordance with the present invention, this embodiment of the universal air pattern controller is preferred. The universal air pattern controller can easily be manufactured using a 3-point roll former or similar equipment without significant deformation or twisting because of the orientation of the neutral axis the even surface relative to the roll-former.
  • These features, and other features and advantages of the present invention will become more apparent to those of ordinary skill in the relevant art when the following detailed description of the preferred embodiments is read in conjunction with the appended drawings in which like reference numerals represent like components throughout the several views.
  • BRIEF DESCRIPTION OF DRAWINGS
  • FIG. 1 is a front perspective view of two universal air pattern controllers positioned in a linear dual slot diffuser with an end cap removed in accordance with the present invention
  • FIG. 2 a is a front elevation view of two universal air pattern controllers positioned in a linear dual slot diffuser with an end cap removed, showing a distal positioning of the universal air pattern controllers and a horizontal direction of airflow.
  • FIG. 2 b is a bottom perspective view of a curved dual slot diffuser showing a distal positioning of the universal air pattern controllers.
  • FIG. 3 is a front cross sectional view of a slot diffuser with a single air slot and a single universal air pattern controller with a fixed mount in an exterior lower position.
  • FIG. 4 is a front cross sectional view of an embodiment of the universal air pattern controller in an adjustable implementation, demonstrating positioning of the universal air pattern controller in a first exterior lower position and the transition path to a second an interior lower position, respectively.
  • FIG. 5 is a front cross sectional view of one half of the slot diffuser of FIG. 1 showing the universal air pattern controller mounted within the slot diffuser with a spring clip.
  • FIG. 6 is an exploded perspective view of the curved dual slot diffuser of FIG. 2 b.
  • FIG. 7 is a perspective view the curved dual slot diffuser of FIG. 2 b, assembled, showing a distal positioning of the universal air pattern controllers with spring clips.
  • DETAILED DESCRIPTION OF INVENTION
  • Illustrative embodiments of a universal air pattern controller 15 for controlling the flow of air from a slot diffuser 10 into an occupied space in accordance with the present invention are shown in FIGS. 1 through 7. Referring to FIGS. 1 and 2A, an exemplary embodiment of a universal air pattern controller 15 is used in conjunction with a two-slot linear air diffuser 10. The slot diffuser 10 comprises two opposing parallel side frames 20 mounted on opposing sides of a center frame 25. The first and second side frames 20 and the center frame 25 include flanges 30 in edgewise opposition to each other to define an elongate discharge air slot 45 therebetween (FIG. 3). It is preferable that the side frames 20 and center frame 25 be constructed from aluminum extrusions.
  • The side frames 20 each have a single narrow longitudinal flange 30 formed as an integral extrusion and extending inwardly toward the air slot 45 at a bottom edge. In one embodiment, side frames 20 further comprise a track 40 having an upper lip 40 a at a top edge and a lower lip 40 b between the top edge and the flange 30, which define a recessed area 41. The track 40 faces inwardly toward the air slot 45, and can be formed integrally with the side frame 20 extrusion, or can be mechanically attached thereto.
  • The center frame 25 is an intermediate wall within the diffuser having a “T-shaped” cross-section, and forms a means for dividing the space between the opposing side frames 20 and a support for the structure. The center frame 25 comprises two narrow longitudinal flanges 30 formed as an integral extrusion, each extending in opposite directions toward a flange 30 of a corresponding side frame 20. Both flanges 30 of the center frame 25 join together to form a continuous surface and create the “T-shape” of the extrusion. The flanges 30 are intended to be mounted in overlapping fashion with adjacent ceiling tiles (not shown) in the ceiling of the occupied space in which the slot diffuser is to be mounted. The center frame 25 also optionally comprises two tracks 40, each having an upper lip 40 a at a top edge and a lower lip 40 b between the top edge and the flanges 30 of the center frame 25, which define recessed areas 43. Each track 40 faces a side frame 20, and can be formed integrally with the center frame 25 extrusion, or can be mechanically attached thereto.
  • The center frame 25 can be mounted to each side frame 20 via a spacer, for example, a dual-sided horizontal H-bar 35. In this embodiment, the H-bar 35 has portions on each side capable of mating with a track 40 on either or both of a side frame 20 or a center frame 25 such that the H-bar 35 is adapted to slidably connect to the side frames 20 and the center frame 25. The center frame 25 is attached to a side frame 20 by slidably mounting the correspondingly-shaped portion on the side of the H-bar 35 into a recessed area 47 (FIG. 5) of the track 40 defined by the upper lip 40 a and lower lip 40 b of the first side frame 20. The H-bar 35 is then slidably mounted in a similar manner to the track 40 on the center frame 25 facing the corresponding first side frame 20. This process is then repeated on the other side to attach the second side frame 20 to the center frame 25. A complete slot diffuser 10 will typically have a spacer such as an H-bar 35 at each end of the diffuser, and can have one or more H-bars 35 spaced therebetween as needed to provide support for the slot diffuser 10 and to keep its component parts in place. The H-bar 35 also functions to provide structural support to the slot diffuser 10. Thus, the H-bar 35 is preferably constructed from a metal material to maintain its rigidity.
  • In other embodiments, as seen in FIGS. 3-4, a linear slot diffuser 10 comprises only two side frames 20 connected to a single H-bar 35 without any center frame 25. In the embodiment shown in FIGS. 3-4, the flanges 30 of the side frames 20 define a single air slot 45. Alternatively, the linear slot diffuser 10 comprises multiple side frames 20 and multiple center frames 25 connected by a corresponding number of H-bars 35. This embodiment would typically define two air slots 45 per pair of side frames 20. FIG. 5 discloses one half of a linear slot diffuser 10 with a side frame 20 and a center frame 25. Optionally, end caps (not shown) can be applied at each end of the diffuser to enhance architectural appeal.
  • The universal air pattern controller 15 in accordance with an embodiment of the present invention comprises one or more elongate, tubular elements 15 mounted within each air slot 45 of the slot diffuser 10. The universal air pattern controller 15 abuts both the flange 30 and the lower lip 40 b of the track 40 of the side frame 20. Preferably, the universal air pattern controller 15 is a single, unitary and enclosed tube with a circular cross section extending substantially the length of the slot diffuser 10. In dual-slot applications, two universal air pattern controllers 15 are mounted distal to the center frame 25. Alternatively, the pair of universal air pattern controllers 15 can be mounted such that each abuts one of the flanges 30 of the center frame 25 and one of the lower lips 40 b of the track 40 of the center frame 25. In this alternative embodiment, both universal air pattern controllers 15 are mounted adjacent to the center frame 25. Also alternatively, any combination of mounting positions can be employed to achieve the desired air flow into the occupied space. In single-slot applications, at least one universal air pattern controller 15 is mounted on either side frame 20 between its corresponding flange 30 and lower lip 40 b in a first position 50 a (shown in FIG. 4) or a second position 50 b depending on the desired direction of air flow.
  • With reference to FIG. 5, the one or more universal air pattern controllers 15, once positioned, can be fixedly or removably attached and held into place with one or more spring clips 55. The spring clip 55 is a thin, flexible piece of wire or other similar molded or shaped hardware suitable for supplying supporting frictional force to urge the universal air pattern controller 15 into engagement with the side frame 20 or center frame 25 and hold it securely into place. In an exemplary embodiment, the spring clip 55 has a profile adapted at a first end 65 to mate with the lower lip 40 b of the track of the side frame 20 or with the lower lip 40 b of the track of the center frame 25, and is adapted at a second end 60 to abut and firmly hold the universal air pattern controller 15 into place. The spring clips 55 in this exemplary embodiment are applied at regular or desired intervals in order to secure the universal air pattern controller 15 in place within the air slot 45. The spring clips 55 are preferably removably attached to the side frame 20 or center frame 25 of the slot diffuser 10 and the universal air pattern controller 15. In alternative embodiments, the spring clips 55 or the universal air pattern controller 15 are fixedly mounted to the side frames 20 or the center frame 25 with a mechanical fastener, such as a nail, screw, or bolt, by welding, or with an adhesive.
  • Referring to FIG. 2A, the universal air pattern controllers 15 are oriented in a position distal to the center frame 25. This orientation directs air flow downward through the air slot 45 and horizontally in a flow direction 70 away from the center frame 25 along the ceiling of an occupied space. Changing the mounting orientation of the universal air pattern controllers 15 to the opposite side of the air slot 45 will serve to direct the air flow in an opposite flow direction 70. The universal air pattern controllers 15 are mountable in a fixed or a removable position either upon installation or during fabrication by manual manipulation and fixation with one or more spring clips 55 as described herein to provide for different flow characteristics such as volume control and directional control.
  • With reference to FIGS. 2B, 6, and 7, an alternative embodiment of the slot diffuser 110 with a universal air pattern controller 115 in accordance with the present invention is shown. The tubular universal air pattern controllers 115 are mounted within the curved slot diffuser 110. At least a portion of the profile of the curved slot diffuser 110 and at least a portion of each air slot 145 is arcuate. Extruded side frames 120 and a center frame 125 are likewise curved, and can be slidably joined at tracks 140 having an upper and lower lip, 140 a and 140 b respectively, by a spacer such as an H-bar 135 in the manner described above. Flanges 130 are preferably unitarily extruded and curved, and define the curved air slot 145. The universal air pattern controllers 115 are mounted along and shaped during fabrication to correspond to the curved profile of the curved slot diffuser 110 and are held in place by one or more spring clips 155 with a first end 165 adapted to abut the universal air pattern controller 115, and a second end 160 adapted to mate with the lower lip 140 a.
  • Traditionally, slot diffusers incorporating complex shapes or special materials required complete re-engineering of the component parts in order to provide an acceptable level of air pattern control. The universal air pattern controllers 15 and 115 in accordance with the present invention have a single design for straight, curved, and shaped slot diffusers 10 and 110, that is easy to manufacture and install and provides superior air pattern control to linear, concave or convex curved, circular, ovular, triangular, and hexagonal applications, for example, without the need to re-engineer and fabricate the working components within the slot diffusers 10 and 110.
  • Preferably, the side frames 20 and the center frame 25 of the slot diffuser 10 used in conjunction with the universal air pattern controller 15 are of a solid extruded aluminum construction. Alternatively, the side frames 20 and the center frame 25 can be constructed of specialized materials for architectural or functional purposes, like stainless steel, brass, bronze, or other materials that would traditionally limit conventional fabrication of the slot diffusers 10 and make the mounting of the universal air pattern controller 15 particularly difficult.
  • The universal air pattern controller 15 is preferably constructed of extruded aluminum. Although building codes and other regulations may restrict the materials that can be used, in certain application, in application where codes and regulations do not so limit the materials to be used, the universal air pattern controller 15 can be constructed from any durable material capable of being bent or shaped to correspond to the contours of the slot diffuser 10. Alternatively, the universal air pattern controller 15 can be constructed from a flexible material such as rubber, plastic, thermoplastic, polypropylene, polyurethane, polyethylene, polyvinyl chloride and the like. The universal air pattern controller 15 can also be constructed of corrugated metal or plastic, braided wire, interlocking metal, multiple flexible layers of material, or incorporate fibrous reinforcement like braided nylon. The universal pattern controller 15 and can be extruded, injection molded, or formed from other methods known in the art, and can be shaped during fabrication, or at any time prior to installation.
  • Because the curved, aerodynamic surface of the universal air pattern controller 15 of the slot diffuser 10 induces a maximized Coand{hacek over (a)} effect at a point just before the fluid leaves the slot diffuser 10, it is capable of creating tight, ceiling-hugging horizontal air patterns as well as vertical air patterns. Also advantageously, the universal air pattern controller 15 can easily be manufactured and shaped using standard equipment like a 3-point roll former without significant deformation or twisting. Though a circular cross section is preferred, the universal air pattern controller 15 can have a cross section that is oval, ovoid, or other substantially rounded shapes. The surface of the universal air pattern controller 15 is preferably smooth, but can alternatively incorporate textures that do not substantially interfere with the air flow across the surface. Finally, the universal air pattern controller 15 need not be completely enclosed to form a true tube, but rather, must be at least substantially enclosed such that the working surface of the universal air pattern controller 15 is continuous.
  • While this invention has been described with reference to preferred embodiments thereof, it is to be understood that variations and modifications can be affected within the spirit and scope of the invention as described herein and as described in the appended claims.

Claims (20)

1. A slot diffuser with a universal air pattern controller suitable for use in any of a curved, angled, linear, or specially-shaped slot diffuser, the device comprising:
a) an air slot diffuser comprising at least two opposing and substantially parallel side frames having top edges and bottom edges, each side frame having a substantially perpendicular inwardly-extending flange at the bottom edge;
b) a spacer connecting the at least two side frames at the top edges, whereby the flanges of the connected side frames define elongate air slots, and
c) one or more elongate, tubular universal air pattern controllers mounted adjacent at least one of the side frames and a corresponding side frame flange.
2. The slot diffuser with a universal air pattern controller of claim 1, wherein the at least two opposing side frames further comprise inwardly-facing tracks adjacent the top edges.
3. The slot diffuser with a universal air pattern controller of claim 2, wherein the tracks further comprise an upper lip and a lower lip, and wherein the upper and lower lip define a recessed area within the tracks.
4. The slot diffuser with a universal air pattern controller of claim 3, wherein the H-bar is adapted to slidably connect to the tracks of the side frames.
5. The slot diffuser with a universal air pattern controller of claim 1, wherein the one or more elongate tubular universal air pattern controllers is mounted to at least one of the side frames by one or more spring clips.
6. The slot diffuser with a universal air pattern controller of claim 1, wherein the one or more elongate tubular universal air pattern controllers is mounted to at least one of the side frames by one or more spring clips; wherein the one or more spring clips comprise a first end and a second end; wherein the first end is adapted to connect to the bottom lip of the track of at least one side frame; wherein the second end is adapted to abut the one or more elongate tubular universal air pattern controllers, and wherein the one or more spring clips apply supporting frictional force to urge the one or more elongate tubular universal air pattern controllers into engagement with at least one side frame and hold the one or more elongate tubular universal air pattern controllers in place.
7. The slot diffuser with a universal air pattern controller of claim 1, wherein the shape of the slot diffuser is linear.
8. The slot diffuser with a universal air pattern controller of claim 1, wherein the shape of at least a portion of the slot diffuser is curved.
9. The slot diffuser with a universal air pattern controller of claim 1, wherein the shape of the slot diffuser incorporates at least one angle.
10. The slot diffuser with a universal air pattern controller of claim 1, wherein the one or more elongate, tubular universal air pattern controllers form a continuous, enclosed tube spanning substantially the length of the slot diffuser.
11. The slot diffuser with a universal air pattern controller of claim 1, wherein the cross section of the one or more elongate, tubular universal air pattern controllers is circular.
12. A slot diffuser with a universal air pattern controller suitable for use in any of a curved, angled, linear, or specially-shaped slot diffuser, the device comprising:
a) an air slot diffuser comprising at least one pair of opposing and substantially parallel side frames having top edges and bottom edges, each side frame having a substantially perpendicular inwardly-extending flange at the bottom edge;
b) at least one center frame between each pair of side frames, each center frame having a top edge and a bottom edge, and each center frame having flanges at the bottom edge extending toward each opposing side frame;
b) a spacer connecting each side frame to the center frame at the top edges, whereby the flanges of the connected side frames and center frame define elongate air slots, and
c) one or more elongate, tubular universal air pattern controllers mounted adjacent at least one side frame or center frame and a corresponding side frame flange or center frame flange.
13. The slot diffuser with a universal air pattern controller of claim 12, wherein the at least one pair of opposing side frames and the at least one center frame further comprise inwardly-facing tracks adjacent the top edges, the tracks further comprising an upper lip adjacent the top edge of the side frame or the center frame, and a lower lip between the upper lip and the bottom edge of the side frame or center frame.
14. The slot diffuser with a universal air pattern controller of claim 13, wherein the spacer is an H-bar adapted to slidably connect to the tracks of the side frames and the tracks of the center frame.
15. The slot diffuser with a universal air pattern controller of claim 13, wherein the one or more elongate tubular universal air pattern controllers are mounted to at least one side frame or the center frame by one or more spring clips.
16. The slot diffuser with a universal air pattern controller of claim 15, wherein the one or more spring clips comprise a first end and a second end; wherein the first end is adapted to connect to the bottom lip of the track of at least one side frame or center frame; wherein the second end is adapted to abut the one or more elongate tubular universal air pattern controllers, and wherein the one or more spring clips apply supporting frictional force to urge the one or more elongate tubular universal air pattern controllers into engagement with at least one side frame or center frame and hold the one or more elongate tubular universal air pattern controllers in place.
17. The slot diffuser with a universal air pattern controller of claim 12, wherein the shape of at least a portion of the slot diffuser is curved.
18. The slot diffuser with a universal air pattern controller of claim 1, wherein the one or more elongate, tubular universal air pattern controllers form a continuous, enclosed tube spanning substantially the length of the slot diffuser, and wherein the cross section of the one or more elongate, tubular universal air pattern controllers is circular.
19. A slot diffuser with a universal air pattern controller suitable for use in any of a curved, angled, linear, or specially-shaped slot diffuser, device comprising:
a) an air slot diffuser with a shape incorporating at least one curve comprising at least two opposing, curved, and substantially parallel extruded side frames having top edges and bottom edges, each side frame having a substantially perpendicular inwardly-extending and unitarily extruded flange at the bottom edge;
b) a spacer connecting the at least two side frames at the top edges, whereby the flanges of the connected side frames define curved, elongate air slots, and
c) one or more elongate, tubular universal air pattern controllers mounted adjacent at least one curved side frame and a corresponding curved side frame flange by at least one spring clip.
20. The slot diffuser with a universal air pattern controller of claim 19, wherein the one or more elongate, tubular universal air pattern controllers forms a continuous, enclosed tube spanning substantially the length of the curved slot diffuser, and wherein the cross section of the one or more elongate, tubular universal air pattern controllers is circular.
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