U.S. patent application number 16/017705 was filed with the patent office on 2019-10-31 for line of sight blocking grille assembly.
The applicant listed for this patent is Air Distribution Technologies IP, LLC. Invention is credited to Patrick R. Barnum, Joseph Spencer Florer, Timothy C. Huggins, Steven J. Purdie, Brian J. Solis.
Application Number | 20190331361 16/017705 |
Document ID | / |
Family ID | 68291177 |
Filed Date | 2019-10-31 |
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United States Patent
Application |
20190331361 |
Kind Code |
A1 |
Solis; Brian J. ; et
al. |
October 31, 2019 |
LINE OF SIGHT BLOCKING GRILLE ASSEMBLY
Abstract
A grille assembly having a housing including a corridor between
a first end and a second end of the housing. The housing may be
fluidly couple with a duct. The grille assembly also includes a
core disposed within the corridor and having a plurality of blades
that may guide fluid flow through the housing and a first portion
of the plurality of blades slanted in a first direction at a first
non-perpendicular angle relative to a corridor axis. The first
portion of the plurality of blades are spaced relative to one
another to form a first plurality of channels that partially pass
through the housing. The grille assembly also includes a second
portion of the plurality of blades slanted in a second direction
that is substantially opposite the first direction at a second
non-perpendicular angle relative to the corridor axis. The second
portion of the plurality of blades are spaced relative to one
another to form a second plurality of channels that partially pass
through the housing and the first and second plurality of channels
are arranged such that a line of sight from the first end to the
second end of the housing is obstructed.
Inventors: |
Solis; Brian J.; (Frisco,
TX) ; Purdie; Steven J.; (Allen, TX) ;
Huggins; Timothy C.; (Durant, OK) ; Barnum; Patrick
R.; (Allen, TX) ; Florer; Joseph Spencer;
(Dallas, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Air Distribution Technologies IP, LLC |
Milwaukee |
WI |
US |
|
|
Family ID: |
68291177 |
Appl. No.: |
16/017705 |
Filed: |
June 25, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62663740 |
Apr 27, 2018 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24F 13/1413 20130101;
F24F 13/142 20130101; F24F 13/28 20130101 |
International
Class: |
F24F 13/14 20060101
F24F013/14; F24F 13/28 20060101 F24F013/28 |
Claims
1. A grille assembly, comprising: a housing including a corridor
between a first end and a second end of the housing, wherein the
housing is configured to fluidly couple with a duct; a core
disposed within the corridor and comprising a plurality of blades
configured to guide fluid flow through the housing; a first portion
of the plurality of blades slanted in a first direction at a first
non-perpendicular angle relative to a corridor axis, wherein the
first portion of the plurality of blades are spaced relative to one
another to form a first plurality of channels that partially pass
through the housing; a second portion of the plurality of blades
slanted in a second direction that is substantially opposite the
first direction at a second non-perpendicular angle relative to the
corridor axis, wherein the second portion of the plurality of
blades are spaced relative to one another to form a second
plurality of channels that partially pass through the housing; and
wherein the first and second plurality of channels are arranged
such that a line of sight from the first end to the second end of
the housing is obstructed.
2. The grille assembly of claim 1, wherein each channel of the
first plurality of channels comprises an inlet adjacent to the
first end and each channel of the second plurality of channels
comprise an outlet adjacent to the second end.
3. The grille assembly of claim 1, wherein the first
non-perpendicular angle and the second non-perpendicular angle are
between approximately 30 degrees and 50 degrees.
4. The grille assembly of claim 1, wherein the first
non-perpendicular angle and the second non-perpendicular angle are
the same.
5. The grille assembly of claim 1, wherein the core comprises a
first core component including the first portion of the plurality
of blades and a second core component abutting the first core
component and including the second portion of the plurality of
blades.
6. The grille assembly of claim 1, comprising a fastener positioned
along the corridor and configured to secure the core within the
housing.
7. The grille assembly of claim 1, comprising a flange disposed at
the first end.
8. The grille assembly of claim 1, wherein the core is removably
coupled to the housing.
9. The grille assembly of claim 1, comprising a third portion of
the plurality of blades slanted in a third direction at a third
non-perpendicular angle relative to the corridor axis, wherein
third portion of the plurality of blades are spaced relative to one
another to form a third plurality of channels that partially pass
through the housing, and wherein the first, second, and third
plurality of channels are arranged such that the line of sight from
the first end to the second end is fully obstructed.
10. A grille assembly, comprising: a housing comprising a corridor
extending from a first end portion to a second end portion of the
housing; a core disposed within the housing comprising: a first
core unit having a first plurality of blades that are each spaced
apart relative to one another along a length of the first core and
slanted in a first direction at a first angle relative to a
corridor axis; and a second core unit comprising a second plurality
of blades that are each spaced apart relative to one another along
a length of the second core unit and slanted in a second direction
at a second angle relative to the corridor axis, wherein the second
core unit is positioned relative to the first core unit such that
the first and second plurality of blades form a plurality of
channels extending from an inlet disposed in the first core unit to
an outlet disposed in the second core unit; and wherein the
plurality of channels are deviated such that a line of sight the
first end portion to the second end portion via the corridor is
obstructed.
11. The grille assembly of claim 10, wherein the first angle and
the second angle are the same.
12. The grille assembly of claim 10, wherein at least one of the
first and second core unit includes cross-wise blades.
13. The grille assembly of claim 10, wherein the first angle and
the second angle is between approximately 35 degrees and 50
degrees.
14. The grille assembly of claim 10, wherein the first core unit
and the second core unit are two separate structures.
15. The grille assembly of claim 10, comprising a third core unit
positioned adjacent the second core unit, wherein the third core
unit comprises a third plurality of blades, each blade is spaced
apart relative to another along a length of the third core unit and
slanted in a third direction at a third angle relative to a
corridor axis, wherein the first, second, and third plurality of
blades form the plurality of channels.
16. The grille assembly of claim 15, wherein the third direction is
different from the first direction.
17. The grille assembly of claim 15, wherein the third angle is
different from the first and second angles.
18. The grille assembly of claim 15, comprising a filter.
19. The grille assembly of claim 10, wherein the first end portion
comprises a flange.
20. A grille assembly, comprising: a first core unit comprising a
first plurality of blades, wherein each blade of the first
plurality of blades is slanted in a first direction at a first
angle relative to a corridor axis of the grille assembly; a second
core unit comprising a second plurality of blades, each blade of
the second plurality of blades is slanted in a second direction at
a second angle relative to the corridor axis, wherein the second
direction is substantially opposite the first directions, and
wherein the second core unit is positioned adjacent the first core
unit such that a first end of each blade of the second plurality of
blades is aligned with a second end of a respective blade of the
first plurality of blades; and a channel extending from an inlet
disposed in the first core unit to an outlet disposed in the second
core unit, wherein each blade of the first and second plurality of
blades are spaced apart relative to one another along the corridor
axis to form the channel, and wherein a line of sight from an inlet
to an outlet of the channel is occluded.
21. The grille assembly of claim 20, wherein the first angle and
the second angle are the same.
22. The grille assembly of claim 20, wherein the first core unit
and the second core unit are welded together.
23. The grille assembly of claim 20, wherein the first angle and
the second angle are between 36 degrees and 50 degrees.
24. The grille assembly of claim 20, wherein the first core unit
and the second core unit are two separate structures.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from and the benefit of
U.S. Provisional Application Ser. No. 62/663,740, entitled "LINE OF
SIGHT BLOCKING GRILLE ASSEMBLY," filed Apr. 27, 2018, which is
hereby incorporated by reference in its entirety for all
purposes.
BACKGROUND
[0002] The present disclosure relates generally to a grille
assembly and, more particularly, to an air grille assembly for an
air duct of a heating, ventilation, and air conditioning (HVAC)
system.
[0003] A wide range of applications exist for HVAC systems. For
example, residential, light commercial, commercial, and industrial
systems are used to control temperatures and air quality in
residences and buildings. HVAC systems include ducts that guide
airflow. Access into and out of these ducts is often provided via
air grille assemblies. As an example, air return ducts remove air
from a room and return the air to the HVAC system. Recycling the
air through the air return duct maintains pressure within the
building or home during operation of the HVAC system. The source
air of the air removed from the room often includes airborne
particulates, such as pollen, dust, and other airborne debris, that
may damage the HVAC system. Accordingly, air grille assemblies are
positioned at an opening of the air return duct or a plenum
positioned upstream of the air return duct to remove large airborne
debris (e.g., a balloon) and conceal the air return duct. In
certain HVAC systems, the air grille assemblies may include a
filter frame having a filter that removes the airborne particulates
from the air before returning the air to an HVAC unit of the HVAC
system. Air grille assemblies may also be used with different ducts
and components of an HVAC system. Such air grille assemblies are
typically located on a wall, ceiling, or floor of a room.
Therefore, the air grille assemblies are generally visible to a
person. It should be noted that air grille assemblies may also be
utilized in conjunction with other features, such as dampers, to
provide products, such as registers for use in HVAC systems. Other
grille assemblies may be employed in different systems to
facilitate, guide, or manage flow.
SUMMARY
[0004] A summary of certain embodiments disclosed herein is set
forth below. It should be understood that these aspects are
presented merely to provide the reader with a brief summary of
these certain embodiments and that these aspects are not intended
to limit the scope of this disclosure. Indeed, this disclosure may
encompass a variety of aspects that may not be set forth below.
[0005] In accordance with a first embodiment, a grille assembly
having a housing including a corridor between a first end and a
second end of the housing. The housing may be fluidly couple with a
duct. The grille assembly also includes a core disposed within the
corridor and having a plurality of blades that may guide fluid flow
through the housing and a first portion of the plurality of blades
slanted in a first direction at a first non-perpendicular angle
relative to a corridor axis. The first portion of the plurality of
blades are spaced relative to one another to form a first plurality
of channels that partially pass through the housing. The grille
assembly also includes a second portion of the plurality of blades
slanted in a second direction that is substantially opposite the
first direction at a second non-perpendicular angle relative to the
corridor axis. The second portion of the plurality of blades are
spaced relative to one another to form a second plurality of
channels that partially pass through the housing and the first and
second plurality of channels are arranged such that a line of sight
from the first end to the second end of the housing is
obstructed.
[0006] In accordance with a second embodiment, a grille assembly
having a housing including a corridor extending from a first end
portion to a second end portion of the housing and a core disposed
within the housing. The core including a first core unit having a
first plurality of blades that are each spaced apart relative to
one another along a length of the first core and slanted in a first
direction at a first angle relative to a corridor axis and a second
core unit including a second plurality of blades that are each
spaced apart relative to one another along a length of the second
core unit and slanted in a second direction at a second angle
relative to the corridor axis. The second core unit is positioned
relative to the first core unit such that the first and second
plurality of blades form a plurality of channels extending from an
inlet disposed in the first core unit to an outlet disposed in the
second core unit and the plurality of channels are deviated such
that a line of sight the first end portion to the second end
portion via the corridor is obstructed.
[0007] In accordance with a third embodiment, a grille assembly
including a first core unit having a first plurality of blades.
Each blade of the first plurality of blades is slanted in a first
direction at a first angle relative to a corridor axis of the
grille assembly. The grill assembly also includes a second core
unit including a second plurality of blades, each blade of the
second plurality of blades is slanted in a second direction at a
second angle relative to the corridor axis. The second direction is
substantially opposite the first directions, and the second core
unit is positioned adjacent the first core unit such that a first
end of each blade of the second plurality of blades is aligned with
a second end of a respective blade of the first plurality of
blades. The grille assembly also includes a channel extending from
an inlet disposed in the first core unit to an outlet disposed in
the second core unit. Each blade of the first and second plurality
of blades are spaced apart relative to one another along the
corridor axis to form the channel, and a line of sight from an
inlet to an outlet of the channel is occluded.
DRAWINGS
[0008] FIG. 1 is a perspective view a heating, ventilating, and air
conditioning (HVAC) system for building environmental management,
in accordance with embodiments described herein;
[0009] FIG. 2 is a perspective view of the packaged HVAC unit of
the HVAC system of FIG. 1, in accordance with embodiments described
herein;
[0010] FIG. 3 is a perspective view of a residential HVAC system,
in accordance with embodiments described herein;
[0011] FIG. 4 is a perspective view of an embodiment of a room side
face of an air grille assembly that may be positioned over an
opening of an air duct of the HVAC system of FIGS. 1 and 3, the air
grille assembly having a core positioned within a corridor and
including a plurality of deviated channels that obstruct visibility
of the air duct, in accordance with embodiments described
herein;
[0012] FIG. 5 is a perspective view of the duct side of the air
grille assembly of FIG. 4, in accordance with embodiments described
herein;
[0013] FIG. 6 is a cross-sectional view of an embodiment of the air
grille assembly of FIG. 4 along line 6-6, whereby the core includes
two rows of blades slanted relative to a corridor axis and that
form the deviated passageways, in accordance with embodiments
described herein;
[0014] FIG. 7 is a cross-sectional view of an embodiment of the air
grille assembly of FIG. 4, whereby the core includes one row of
blades positioned orthogonal to the corridor axis and two rows of
blades slanted relative to the corridor axis to form the deviated
channel, the blades in each respective row of the two slanted rows
are slanted in opposite directions, in accordance with embodiments
described herein; and
[0015] FIG. 8 is a cross-sectional view of an embodiment of the air
grille assembly of FIG. 4, whereby the core includes one row of
blades positioned orthogonal to the corridor axis and two rows of
blades slanted relative to the corridor axis to form the deviated
passageway, the blades in each respective row of the two slanted
rows are slanted in the same direction, in accordance with
embodiments described herein.
DETAILED DESCRIPTION
[0016] The present disclosure is directed toward grille assemblies
and, more particularly, air grille assemblies for use with air
ducts of heating, ventilation, and air conditioning (HVAC) systems.
For example, air grille assemblies of the present disclosure
conceal an air duct or open plenum space by completely or partially
obstructing a line of sight through the air grille assembly from a
room side to a duct side/plenum side of the air grille assembly.
Additionally, the air grille assemblies disclosed herein may
include a filter utilized to remove air and airborne particulates
from a room and return air to an HVAC unit of the HVAC system via
the air return duct. The disclosed air grille assemblies include a
core having stacked rows of blades that are arranged in a manner
that forms a deviated channel, or V-shaped channel, from a room
side inlet to a duct side outlet of the air grille assembly. The
deviated channel obstructs a line of sight of an observer looking
into the air grille assembly from at any location within the room.
As such, the disclosed air grille assembly improves the appearance
and aesthetics of a room with a return air grille. It should be
noted that while the discussion of present embodiments is generally
provided in the context of air grille assemblies for air return
ducts, the disclosed air grille assemblies can also be used with
other features, such as air supply ducts. Indeed, grille assemblies
in accordance with present embodiments may be used with various
ducts, which may include different types of channels and flow
paths.
[0017] Turning now to the drawings, FIG. 1 illustrates a heating,
ventilation, and air conditioning (HVAC) system for building
environmental management that may employ one or more HVAC units and
air grille assemblies in accordance with present embodiments. In
the illustrated embodiment, a building 10 is air conditioned by a
system that includes an HVAC unit 12. The building 10 may be a
commercial structure or a residential structure. As shown, the HVAC
unit 12 is disposed on the roof of the building 10; however, the
HVAC unit 12 may be located in other equipment rooms or areas
adjacent the building 10. The HVAC unit 12 may be a single package
unit containing other equipment, such as a blower, integrated air
handler, and/or auxiliary heating unit. In other embodiments, the
HVAC unit 12 may be part of a split HVAC system, such as the system
shown in FIG. 3, which includes an outdoor HVAC unit 58 and an
indoor HVAC unit 56.
[0018] The HVAC unit 12 is an air cooled device that implements a
refrigeration cycle to provide conditioned air to the building 10.
Specifically, the HVAC unit 12 may include one or more heat
exchangers across which an air flow is passed to condition the air
flow before the air flow is supplied to the building. In the
illustrated embodiment, the HVAC unit 12 is a rooftop unit (RTU)
that conditions a supply air stream, such as environmental air
and/or a return air flow from the building 10. After the HVAC unit
12 conditions the air, the air is supplied to the building 10 via
ductwork 14 extending throughout the building 10 from the HVAC unit
12. For example, the ductwork 14 may extend to various individual
floors or other sections of the building 10. In certain
embodiments, the HVAC unit 12 may be a heat pump that provides both
heating and cooling to the building with one refrigeration circuit
configured to operate in different modes. In other embodiments, the
HVAC unit 12 may include one or more refrigeration circuits for
cooling an air stream and a furnace for heating the air stream.
[0019] A control device 16, one type of which may be a thermostat,
may be used to designate the temperature of the conditioned air.
The control device 16 also may be used to control the flow of air
through the ductwork 14. For example, the control device 16 may be
used to regulate operation of one or more components of the HVAC
unit 12 or other components, such as dampers and fans, within the
building 10 that may control flow of air through and/or from the
ductwork 14. In some embodiments, other devices may be included in
the system, such as pressure and/or temperature transducers or
switches that sense the temperatures and pressures of the supply
air, return air, and so forth. Moreover, the control device 16 may
include computer systems that are integrated with or separate from
other building control or monitoring systems, and even systems that
are remote from the building 10.
[0020] FIG. 2 is a perspective view of an embodiment of the HVAC
unit 12. In the illustrated embodiment, the HVAC unit 12 is a
single package unit that may include one or more independent
refrigeration circuits and components that are tested, charged,
wired, piped, and ready for installation. The HVAC unit 12 may
provide a variety of heating and/or cooling functions, such as
cooling only, heating only, cooling with electric heat, cooling
with dehumidification, cooling with gas heat, or cooling with a
heat pump. As described above, the HVAC unit 12 may directly cool
and/or heat an air stream provided to the building 10 to condition
a space in the building 10.
[0021] As shown in the illustrated embodiment of FIG. 2, a cabinet
24 encloses the HVAC unit 12 and provides structural support and
protection to the internal components from environmental and other
contaminants. In some embodiments, the cabinet 24 may be
constructed of galvanized steel and insulated with aluminum foil
faced insulation. Rails 26 may be joined to the bottom perimeter of
the cabinet 24 and provide a foundation for the HVAC unit 12. In
certain embodiments, the rails 26 may provide access for a forklift
and/or overhead rigging to facilitate installation and/or removal
of the HVAC unit 12. In some embodiments, the rails 26 may fit into
"curbs" on the roof to enable the HVAC unit 12 to provide air to
the ductwork 14 from the bottom of the HVAC unit 12 while blocking
elements such as rain from leaking into the building 10.
[0022] The HVAC unit 12 includes heat exchangers 28 and 30 in fluid
communication with one or more refrigeration circuits. Tubes within
the heat exchangers 28 and 30 may circulate refrigerant through the
heat exchangers 28 and 30. For example, the refrigerant may be
R-410A. The tubes may be of various types, such as multichannel
and/or microchannel tubes, conventional copper or aluminum tubing,
and so forth. Together, the heat exchangers 28 and 30 may implement
a thermal cycle in which the refrigerant undergoes phase changes
and/or temperature changes as it flows through the heat exchangers
28 and 30 to produce heated and/or cooled air. For example, the
heat exchanger 28 may function as a condenser where heat is
released from the refrigerant to ambient air, and the heat
exchanger 30 may function as an evaporator where the refrigerant
absorbs heat to cool an air stream. In other embodiments, the HVAC
unit 12 may operate in a heat pump mode where the roles of the heat
exchangers 28 and 30 may be reversed. That is, the heat exchanger
28 may function as an evaporator and the heat exchanger 30 may
function as a condenser. In further embodiments, the HVAC unit 12
may include a furnace for heating the air stream that is supplied
to the building 10. While the illustrated embodiment of FIG. 2
shows the HVAC unit 12 having two of the heat exchangers 28 and 30,
in other embodiments, the HVAC unit 12 may include one heat
exchanger or more than two heat exchangers.
[0023] The heat exchanger 30 is located within a compartment 31
that separates the heat exchanger 30 from the heat exchanger 28.
Fans 32 draw air from the environment through the heat exchanger
28. Air may be heated and/or cooled as the air flows through the
heat exchanger 28 before being released back to the environment
surrounding the rooftop unit 12. A blower assembly 34, powered by a
motor 36, draws air through the heat exchanger 30 to heat or cool
the air. The heated or cooled air may be directed to the building
10 by the ductwork 14, which may be connected to the HVAC unit 12.
Before flowing through the heat exchanger 30, the conditioned air
flows through one or more filters 38 that may remove particulates
and contaminants from the air. In certain embodiments, the filters
38 may be disposed on the air intake side of the heat exchanger 30
to prevent contaminants from contacting the heat exchanger 30.
[0024] The HVAC unit 12 also may include other equipment for
implementing the thermal cycle. Compressors 42 increase the
pressure and temperature of the refrigerant before the refrigerant
enters the heat exchanger 28. The compressors 42 may be any
suitable type of compressors, such as scroll compressors, rotary
compressors, screw compressors, or reciprocating compressors. In
some embodiments, the compressors 42 may include a pair of hermetic
direct drive compressors arranged in a dual stage configuration 44.
However, in other embodiments, any number of the compressors 42 may
be provided to achieve various stages of heating and/or cooling. As
may be appreciated, additional equipment and devices may be
included in the HVAC unit 12, such as a solid-core filter drier, a
drain pan, a disconnect switch, an economizer, pressure switches,
phase monitors, and humidity sensors, among other things.
[0025] The HVAC unit 12 may receive power through a terminal block
46. For example, a high voltage power source may be connected to
the terminal block 46 to power the equipment. The operation of the
HVAC unit 12 may be governed or regulated by a control board 48.
The control board 48 may include control circuitry connected to a
thermostat, sensors, and alarms. One or more of these components
may be referred to herein separately or collectively as the control
device 16. The control circuitry may be configured to control
operation of the equipment, provide alarms, and monitor safety
switches. Wiring 49 may connect the control board 48 and the
terminal block 46 to the equipment of the HVAC unit 12.
[0026] FIG. 3 illustrates a residential heating and cooling system
50, also in accordance with present techniques. The residential
heating and cooling system 50 may provide heated and cooled air to
a residential structure, as well as provide outside air for
ventilation and provide improved indoor air quality (IAQ) through
devices such as ultraviolet lights and air filters. In the
illustrated embodiment, the residential heating and cooling system
50 is a split HVAC system. In general, a residence 52 conditioned
by a split HVAC system may include refrigerant conduits 54 that
operatively couple the indoor unit 56 to the outdoor unit 58. The
indoor unit 56 may be positioned in a utility room, an attic, a
basement, and so forth. The outdoor unit 58 is typically situated
adjacent to a side of residence 52 and is covered by a shroud to
protect the system components and to prevent leaves and other
debris or contaminants from entering the unit. The refrigerant
conduits 54 transfer refrigerant between the indoor unit 56 and the
outdoor unit 58, typically transferring primarily liquid
refrigerant in one direction and primarily vaporized refrigerant in
an opposite direction.
[0027] When the system shown in FIG. 3 is operating as an air
conditioner, a heat exchanger 60 in the outdoor unit 58 serves as a
condenser for re-condensing vaporized refrigerant flowing from the
indoor unit 56 to the outdoor unit 58 via one of the refrigerant
conduits 54. In these applications, a heat exchanger 62 of the
indoor unit functions as an evaporator. Specifically, the heat
exchanger 62 receives liquid refrigerant, which may be expanded by
an expansion device, and evaporates the refrigerant before
returning it to the outdoor unit 58.
[0028] The outdoor unit 58 draws environmental air through the heat
exchanger 60 using a fan 64 and expels the air above the outdoor
unit 58. When operating as an air conditioner, the air is heated by
the heat exchanger 60 within the outdoor unit 58 and exits the unit
at a temperature higher than it entered. The indoor unit 56
includes a blower or fan 66 that directs air through or across the
indoor heat exchanger 62, where the air is cooled when the system
is operating in air conditioning mode. Thereafter, the air is
passed through ductwork 68 that directs the air to the residence
52. The overall system operates to maintain a desired temperature
as set by a system controller. When the temperature sensed inside
the residence 52 is higher than the set point on the thermostat, or
the set point plus a small amount, the residential heating and
cooling system 50 may become operative to refrigerate additional
air for circulation through the residence 52. When the temperature
reaches the set point, or the set point minus a small amount, the
residential heating and cooling system 50 may stop the
refrigeration cycle temporarily.
[0029] The residential heating and cooling system 50 may also
operate as a heat pump. When operating as a heat pump, the roles of
heat exchangers 60 and 62 are reversed. That is, the heat exchanger
60 of the outdoor unit 58 will serve as an evaporator to evaporate
refrigerant and thereby cool air entering the outdoor unit 58 as
the air passes over the heat exchanger 60. The indoor heat
exchanger 62 will receive a stream of air blown over it and will
heat the air by condensing the refrigerant.
[0030] In some embodiments, the indoor unit 56 may include a
furnace system 70. For example, the indoor unit 56 may include the
furnace system 70 when the residential heating and cooling system
50 is not configured to operate as a heat pump. The furnace system
70 may include a burner assembly and heat exchanger, among other
components, inside the indoor unit 56. Fuel is provided to the
burner assembly of the furnace 70 where it is mixed with air and
combusted to form combustion products. The combustion products may
pass through tubes or piping in a heat exchanger, separate from
heat exchanger 62, such that air directed by the blower 66 passes
over the tubes or pipes and extracts heat from the combustion
products. The heated air may then be routed from the furnace system
70 to the ductwork 68 for heating the residence 52.
[0031] FIGS. 4 and 5 illustrate an embodiment of an air grille
assembly 80 that can be positioned over an open end of a duct, such
as an air return duct, or a plenum upstream of the duct associated
with any of the systems described above. FIG. 4 illustrates a room
side end face 82 of the air grille assembly 80, and FIG. 5
illustrates a duct/plenum side end face 84 of the air grille
assembly 80. In one embodiment, the air grille assembly 80 operates
to return air to the HVAC unit 12 via the air return duct of the
HVAC system. Additionally, the air grille assembly 80 conceals the
air return duct, which improve the aesthetics of the room.
[0032] The air grille assembly 80 includes a housing 86 having a
flange 90 on the room side end face 82 and a corridor 92 extending
away from the flange 90 toward the duct/plenum side end face 84.
The corridor 92 may be a single wall or an assembly of walls that
forms a channel 94 that allows airflow therethrough. For example,
air from a room may flow into an air return duct or plenum of the
HVAC system via the channel 94. The channel 94 defines a room side
opening 96 and a duct side opening 97. The channel 94 is sized to
fit within an open end of a duct, such as an air return duct, of
the HVAC system. The flange 90 extends a distance 99 away from the
corridor 92 to facilitate coupling of the air grille assembly 80 to
a wall, ceiling, or floor of a room. The flange 90 extends a
distance 99 away from the corridor 92 to facilitate installation of
the air grille assembly 80 into a T-Bar lay in ceiling grid system.
For example, once positioned over the open end of an air return
duct, the air grille assembly 80 may be secured onto a desired
surface by inserting a coupling member into a receptacle 101 of the
flange 90. By way of non-limiting example, the coupling member may
include a nail, screw, bolt, or any other suitable coupling member
that can be used to secure the air grille assembly 80 to the
desired surface. In certain embodiments, the air grille assembly 80
may be installed in a ceiling T-Bar grid system with no return air
ductwork.
[0033] In the illustrated embodiment, a core 98 is nested within
the channel 94 of the corridor 92 such that the core is generally
adjacent or forms part of the room side end face 82. The room side
opening 96 may have a dimension 100 that is smaller than a
dimension 102 of the duct side opening 97. For example, a perimeter
or length of the room side opening 96 may be incrementally smaller
than a respective perimeter or length of the duct side opening 97.
The core 98 may be inserted into the corridor 92 through the duct
side opening 97 and sized to fit within the channel 94. The
dimensions of the core 98 are larger than the dimension 100 of the
room side opening 96 such that the core 98 is unable to fit through
the room side opening 96. The smaller dimension 100 of the room
side opening 96 creates an abutment surface in the channel 94 that
supports the core 98 within the housing 86.
[0034] The core 98 may be secured within the channel 94 via
fasteners 104 disposed on the corridor 92 of the housing 86. In
certain embodiments, the fasteners 104 include a deformable tab or
cantilever that may be moved from a first position that is parallel
to a corresponding feature of the corridor 92 to a second position
that is orthogonal to a corresponding feature of the corridor 92.
In the second position, the deformable tab abuts against a duct
side end of the core 98 to secure the core 98 within the channel
94. In other embodiments, the fasteners 104 may include resilient
tabs that secure the core 98 in the channel 94 via a snap-fit
mechanism. In certain embodiments, the air grille assembly 80 may
include a filter adjacent to the core 98 on the duct side end of
the core 98. The filter may capture additional airborne
particulates that may have flowed into the air grille assembly 80.
Additionally, the filter may occlude any portion of the air duct
that may remain visible through the air grille assembly 80.
[0035] The core 98 includes features that may conceal the duct side
of the air grille assembly 80 from an observer on the room side.
For example, the core 98 includes a plurality of blades 106, 107.
The blades 106, 107 form a grid pattern that divides the channel 94
into a plurality of deviated channels 108. That is, the blades 106,
107 are arranged in a cross-wise configuration. The deviated
channels 108 direct airflow through the air grille assembly 80 to a
desired location, such as to the air return duct of the HVAC
system. As discussed in further detail below, the deviated channels
108 completely or partially obstruct visibility through the air
grille assembly (such as into the air return duct) when an observer
is looking into the air grille assembly 80 from any location within
the room. For example, a configuration of the deviated channels 108
may result in a visibility through the air grille assembly 80 that
is between 0% and approximately 20%. In certain embodiments, the
core 98 includes a filer frame having a filter that facilitates
removal of airborne particulates in air passing therethrough and
conceals the dust side of the air grille assembly 80 from an
observer on the room side.
[0036] FIG. 6 is a cross-sectional view of an embodiment of the air
grille assembly 80 in which the blades 106 are oriented at a
non-perpendicular angle 112 relative to a corridor axis 114 of the
core 98, and the blades 107 are oriented orthogonal to the corridor
axis 114. It should be noted that the corridor axis 114 is
generally transverse, or orthogonal, to a flow path of air through
the corridor 92, as it would be without the core 98 disposed
therein. The blades 106 are slanted and the blades 107 are at an
angle of approximately 90 degrees relative to the corridor axis 114
when considered from a common perspective. The blades 107 are
spaced apart (evenly in the illustrated embodiment) along the
dimension 100 and run orthogonal to the blades 106 along their
length, thereby forming the grid pattern and splitting the channel
94 into the deviated channels 108. It should be noted that the
blades 107 are now shown in the cross-sectional view of FIG. 6 but
form border walls of at least portions of the deviated channels 108
in certain embodiments.
[0037] The slanted orientation of the blades 106 obstruct a line of
sight 118 through the air grille assembly 80 from the room side
face 82 to the duct side face 84, thereby concealing the associated
duct from observation from the room. For example, the core 98
includes a first row 102a having the plurality of blades 106a
extending along a length 122 of the channel 94 and slanted in a
first direction 124 such that each blade 106a is oriented at the
non-perpendicular angle 112a relative to the corridor axis 114. A
second row 102b having the plurality of blades 106b extending along
the length 122 is positioned above the first row 120a such that
each blade 106b in the second row 102b is aligned with a respective
blade 106a in the first row 102a. The blades 106b in the second row
102b are slanted in a second direction 128 that is substantially
opposite the first direction 124. As such, similar to the blades
106a, each blade 106b is oriented at the non-perpendicular angle
112b. By way of non-limiting example, the non-perpendicular angle
112 is between approximately 35 degrees and 50 degrees. In certain
embodiments, the non-perpendicular angle 112a, 112b is the same. In
other embodiments, the non-perpendicular angle 112a is different
from the non-perpendicular angle 112b. For example, the
non-perpendicular angle 112a may be 45 degrees and the
non-perpendicular angle 112b may be 40 degrees.
[0038] The opposing slanted orientation between the blades 106a,
106b in each respective row 102a, 102b creates the deviated channel
108 and partially or completely obstructs the line of sight 118
into the duct through the air grille assembly 80. For example, in
the illustrated embodiment, an end 130b of each blade 106b in the
second row 102b is aligned with the end 130a of an adjacent blade
106a in the first row 102a. As such, each blade 106b in the second
row 102b extends over an inlet 132 of the deviated channel 108 in a
manner that obstructs a view of the air duct through an outlet 134
of the deviated channel 108. However, in other embodiments, the
ends 130a, 130b of each respective blade 106a, 106b are not
aligned. For example, in certain embodiments, the blades 106b may
be slanted such that the non-perpendicular angle 112b is less than
45 degrees. Therefore, the end 130b may extend past the end 130a of
a respective adjacent blade 106a. In one embodiment, the end 130b
of the blade 106b is aligned with an end 140 of an adjacent blade
106a in the first row 102a.
[0039] The core 98 may include any number of rows of the blades
106. Each row 102a, 102b may be a separate structure. For example,
the core 98 may include core units that make up a single row 102a,
102b of the blades 106a, 106b. The core units are separate pieces
that may be stacked one on top of another to form the deviated
channel 108. In certain embodiments, the core units may be welded
together to form a single structure. Any number of core units may
be stacked within the housing 86 of the air grille assembly 80. For
example, FIGS. 7 and 8 illustrate an air grille assembly 150 having
a core 152 that includes three rows 154, or core units, of the
blades 106. The core unit also includes the blades 107 arranged in
a cross-wise configuration relative to the blades 106. In the
illustrated embodiments, the blades 106a in the first row 154a are
positioned orthogonal (e.g., at a 90 degree angle relative to the
corridor axis 114). However, the blades 106 in the subsequent rows
154b, 154c are slanted, thereby creating the deviated channel 108
and obstructing the line of sight 118 through the air grille
assembly 150 and into the air duct of the HVAC system.
[0040] In certain embodiments, the blades 106b, 106c in the
respective rows 154b, 154c are slanted in opposite directions. For
example, as shown in FIG. 7, the blades 106b in the second row 154b
are slanted in the direction 128 and the blades 106c in the third
row 154c are slanted in the substantially opposite direction 124.
However, in other embodiments, the blades 106b, 106c in each
respective row 154b, 154c are slanted in the same direction 124,
128, as shown in FIG. 8. The blades 106b, 106c may be slanted such
that the non-perpendicular angle 112b, 112c relative to the
corridor axis 114 is between approximately 35 degrees and 50
degrees. The non-perpendicular angle 112b, 112c may be the same or
different in the rows 154b, 154c. In certain embodiments, each
blade 106c is slanted such that the respective end 130c is aligned
with the end 130a of a respective blade 106a in the first row 154a
or the end 130b of an adjacent blade 106b in the second row 154b.
In this way, each blade 106c in the third row 154c partially or
completely obstructs the line of sight 118 from the inlet 132 to
the outlet 134. Accordingly, for example, when the air grille
assembly 80 is utilized as an access port for an air duct of an
HVAC system, the air duct cannot be viewed via the air grille
assembly 80 by a person at any location within the room.
[0041] As discussed above, one or more of the disclosed embodiments
may provide one or more technical effects useful in HVAC systems
associated with the use air grille assemblies. For example, the
disclosed embodiments of the present approach may facilitate
concealing the air duct or air plenum of the HVAC systems. By
specific example, the air grille assembly may include a core having
rows of blades stacked on top of one another where the blades in
each row are slanted to form a deviated channel that extends from a
room side face to a duct/plenum side face of the air grille
assembly. The blades in the row adjacent to the duct/plenum side
face of the air grille assembly block a line of sight from the
inlet to the outlet of the deviated channel. As such, the
associated duct/plenum is not visible when looking into the air
grille assembly from any location within the room. It should be
noted that the embodiments described in the specification may have
other technical effects and can solve other technical problems.
[0042] While only certain features and embodiments of the invention
have been illustrated and described, many modifications and changes
may occur to those skilled in the art (e.g., variations in sizes,
dimensions, structures, shapes and proportions of the various
elements, values of parameters (e.g., temperatures, pressures,
etc.), mounting arrangements, use of materials, colors,
orientations, etc.) without materially departing from the novel
teachings and advantages of the subject matter recited in the
claims. The order or sequence of any process or method steps may be
varied or re-sequenced according to alternative embodiments. It is,
therefore, to be understood that the appended claims are intended
to cover all such modifications and changes as fall within the true
spirit of the invention. Furthermore, in an effort to provide a
concise description of the exemplary embodiments, all features of
an actual implementation may not have been described (i.e., those
unrelated to the presently contemplated best mode of carrying out
the invention, or those unrelated to enabling the claimed
invention). It should be appreciated that in the development of any
such actual implementation, as in any engineering or design
project, numerous implementation specific decisions may be made.
Such a development effort might be complex and time consuming, but
would nevertheless be a routine undertaking of design, fabrication,
and manufacture for those of ordinary skill having the benefit of
this disclosure, without undue experimentation.
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