AU727459B2 - An improved air outlet grille assembly - Google Patents

Description

Regulation 3.2

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A PATENT OF ADDITION

ORIGINAL

pplicant: Actual Inventor: ANDREW ROGERS Address for Service: MADDERNS, 1st Floor, 64 Hindmarsh Square, Adelaide, South Australia, Australia Invention title: AN IMPROVED AIR OUTLET GRILLE ASSEMBLY Details of Associated Provisional Application No: PO 2008 dated 30 August 1996 The following statement is a full description of this invention, including the best method of performing it known to us.

1 F %3obI0s -Z 9 Q a P Se)? This invention relates to an improved air diffuser assembly for use in conjunction with air conditioning or ventilating equipment, wherein the diffuser is mounted in a ceiling for directing a supply of air from the air conditioning or ventilating equipment into a space or room.

In our Australian Patent No 663412, there is described an air diffuser assembly which comprises a moulded main frame which at its lower end is formed with a downwardly opening recessed section, its upper end being formed as a neck adaptor for connection to the end of a duct, a plurality of modular core elements which are adapted to be releasably secured together in side-by-side horizontally aligned relationship (prior to their fitment into the frame) and which are subsequently releasably attached as an assembly within the recessed section, the pre-assembly of the modular core elements being designed to allow the desired air delivery pattern to be simply arranged. It has now been found that the complementary securing means used to releasably secure the S 15 modular core elements together in side-by-side relationship need to be quite substantial in order to ensure that the core elements, when fitted together, remain truly horizontal Sand, for example, do not drop or "sink" in the centre region of the assembly (due to their weight). Furthermore it has also been found that due to the somewhat intricate moulded shapes which are required for the outer frame members of each of the modular core elements for the purpose of joining them together and in turn snap fitting the sub-assembly within the recessed section of the main frame, the tooling costs for moulding the core elements are significantly high.

Still further, it is now considered that the overall visual appearance of the assembled core elements within the main frame is not overly satisfactory in that the mating joining edges between adjacent core modules are visible and exposed to view. Any gaps between the joins tend to detract from the overall visual appearance of the installation.

A still further disadvantage with that earlier system is that the core elements, due in particular to the upstanding latching tongues which are formed on each of the four sides of its frame centrally thereof, cannot be economically and conveniently packaged, particularly in large numbers.

It is now realised that by utilising an arrangement wherein the separate core elements are individually supported in position by means of a separate insert frame which can then be inserted upwardly into the recessed section of the main frame and snap fittingly located in position rather than relying on separate latching members co-operating with latch engaging surfaces formed around the walls forming the recessed section, not only is there a significant saving in tooling costs, but also the aesthetic appearance of the assembly is improved.

According to this invention therefore, there is provided an air diffuser assembly of the kind comprising an outer main frame which is formed with walls defining a central downwardly opening recessed section at its lower end, and a plurality of separate modular core elements which are arranged to be housed within said recessed section of the main frame, wherein each core element comprises a square or rectangular 15 peripheral frame supporting a plurality of curved air deflector blades between opposite sides thereof, the improvement wherein the modular core elements are supported by a Sseparate insert frame having a peripheral shape complementary to that of said recessed section, said insert frame comprising outer peripheral frame members and a pair of cross-wise disposed inverted T-shaped inner frame members each extending between respective opposite sides of the insert frame centrally thereof, said inner frame members forming with said outer frame members a plurality of core element receiving pockets or cavities in which the individual core elements are loosely seated when in S"their installed positions, and interlocking means between the insert frame and the main frame for releasably securing the insert frame within said recessed section of the main frame, whereby the core elements can be separately positioned within their respective cavities or pockets so as to provide the selected air delivery pattern, and thereafter the insert frame, along with the core elements, can be inserted upwardly as a sub-assembly into the open lower end of the main frame and snap fittingly located therein.

Desirably, the interlocking means comprises co-operable latch and latch engaging means on the outer peripheral frame members of the insert frame and the walls defining said central recessed section respectively.

In a preferred embodiment of the invention, each of the outer frame members of the insert frame is provided with one or more resiliently deflectable tongues or fingers formed therein, each tongue or finger having a tooth or projection at or adjacent its free end, the teeth or projections on the latching fingers being arranged to latchingly engage within openings or apertures formed in the walls which define said recessed section when the insert frame is pushed upwardly thereinto. The latching arms or fingers, being resiliently deflectable, can be disengaged from their respective latch engaging surfaces in order to permit the insert frame to be separated from the main frame.

Preferably each of the outer frame members of the insert frame also has an inverted T-shape, whereby the insert frame is provided with an approximately planar flange which extends continuously around its perimeter on the underside thereof. Preferably the horizontal flange of each of the inverted T-shaped cross-members is slightly greater S 15 in width than the width of the outer perimeter flange.

Preferably the outer main frame terminates at its open bottom end in an outwardly directed lateral peripheral flange which, when the assembly is fitted into a ceiling, is arranged to firmly bear against the underside surface of the ceiling. Preferably the lateral peripheral flange terminates along its inner periphery in a rebate or shoulder in which the outwardly flanged edges of the outer frame members of the insert frame are located, when the insert frame is installed, whereby the peripheral flange on the main frame and the outer peripheral flange on the insert frame are approximately flush with one another.

With the diffuser assembly of the present invention, the design construction of each of the modular core elements is greatly simplified and can be produced with significantly lower tooling costs in comparison to the arrangement described in our earlier Patent 663412 there being no requirement for intricate latching tongues on each of the four sides of the core element nor for any dove-tail projections and recesses around their outer sides.

By having a separate releasably attachable insert frame in which the core elements are removably seated, the advantage of being able to install the main outer frame in the ceiling while having free and unimpeded access to its interior (ie with the insert frame detached therefrom) is still achieved. This of course is not the case with one well known diffuser assembly wherein the outer frame and the inverted T-shaped crossmembers provided at its open bottom end in order form the pockets or cavities for receiving the core elements are integrally moulded together. The cross-members impede or restrict access into the interior of the main frame during installation when mounting clips are required to be inserted from inside of the main frame and passed outwardly through holes formed in its walls, and which serve to hold the main frame in position within its opening in the ceiling.

In order to more fully describe and explain the present invention, a preferred S. embodiment thereof is described hereunder in some further detail with reference to the S 15 accompanying drawing which is an exploded perspective view of the diffuser assembly.

In this embodiment, an air diffuser assembly 10 comprises an integrally moulded main frame 11, a separate integrally moulded square insert frame 12 which is designed to snugly fit into the open lower end of the main frame 11, and a plurality of modular core elements 13 (in this embodiment there being four such elements 13) which are removably supported in respective cavities or pockets 14 formed within the insert frame 12.

The main frame 11 is arranged to be removably installed in an opening 15 in the ceiling 16 of a room into which conditioned air is to be passed. The main frame 11 is held in position by means of a plurality of approximately U-shaped resilient spring clips 18 which are arranged to project through and be retained within apertures 19 formed in walls of the main frame 11. With the clips 18 fully engaged in position, the bridge portion thereof makes pressure contact against the rear surface of the ceiling 16, with the inner ends of the clip 18 lockingly engaging respective engagement surfaces located interiorly of the frame 11. This arrangement is substantially in accordance with that described and illustrated in Australian Patent 663412.

The main frame 11 is provided with a square downwardly opening recessed section 22 having a shape complementary to that of the insert frame 12, the recessed section 22 being formed by the four side walls 20 which extend around the perimeter of the frame 11. The recessed section 22 merges with a cylindrical neck adaptor 25 which is formed by a plurality of circular coupling formations of different diameters to which is coupled an air supply duct (not shown) from which air is delivered to the diffuser assembly and in turn into the room or space being conditioned or ventilated.

The lower end of the recessed section 22 comprises an out-turned shoulder 27 which extends around the perimeter of the opening defined by the recessed section 22, the shoulder 27 in turn joining to an outwardly directed lateral peripheral flange 28 which, when the assembly 10 is fitted into the ceiling, is arranged to firmly bear against the o• underside surface of the ceiling 16.

.o e Each of the side walls 20 is provided with a pair of spaced apart slot-like apertures intermediate the upper and lower edges thereof, the purpose of which will be explained hereinafter.

The insert frame 12 which snap fits within the recessed section 22 of the frame 11 comprises a square frame formed by inverted T-shaped outer frame members 32, the square frame being divided into four upwardly opening recesses or pockets 14 by means of a pair of cross-wise disposed inverted T-shaped inner frame members 33 which intersect at right angles to one another. The flanged edges of the members 32, 33 form seating surfaces for seatingly locating the bottom flanged periphery 36 of each of the core elements 13. It will of course be appreciated that each of the core elements 13 is positioned in its respective pocket or cavity 14 from above the frame 12.

The outwardly flanged edges 38 of the outer frame members 32 are designed to snugly engage in the recesses formed by the peripheral shoulder 27 so that they lie flush (or nearly so) with the bottom peripheral flange 28 of the main housing 11.

It will of course be realised that the flanges on the inner frame members 33 ensure that the gaps between the adjacent sides of the core elements 13 are effectively concealed.

In accordance with a feature of this invention, each of the outer frame members 32 of the insert frame 12 is provided with a pair of resiliently deflectable latching tongues or fingers 40, each of which is provided on its outer face with a latching tooth or projection 41 which, when the frame 12 is inserted within the main frame 11, lockingly engages against an edge surface of a latching aperture 30 formed in the side walls 20 of the frame 11. This snap fitting engagement between the insert frame 12 and the main frame 9. o99 9 11 allows the insert frame 12 to be easily and readily mounted in the frame 11 and also 15 demounted therefrom.

S• In accordance with known art, each of the modular core elements 13 comprises a square frame, and a plurality of curved deflector blades 42 each pivotally mounted at its opposite ends in pivot holes formed in opposite side frame members 43 of the square frame. In this embodiment the curved blades 42 move simultaneously by virtue of a pair of connector bars 44 which connect to lugs integrally formed on opposite ends of the blades 42. This ensures that the position of the blades can be readily adjusted so as to adjust the direction of delivery of the air from the diffuser The installation of the diffuser assembly 10 is quite simple. The main frame or housing 11 is inserted into the opening 15 in the ceiling 16 and retained in position by means of the mounting clips 18. Thereafter the modular core elements 13 are seated inside of the insert frame 12 in order to provide the desired air delivery pattern, and the insert frame 12, along with the core elements 13, is pushed upwardly into the recessed section 22 of the main frame 11 and clipped into place. If the orientation of any one of the core elements 13 is needed to be changed, one simply lifts the core element from its seated position to a position whereat it can then be rotated in order to rearrange its orientation and then lowered again to its seating position within the insert frame 12.

In a variation of the above described embodiment, the interlocking of the insert frame to the main frame may be effected by means of a snap-fit between the peripheral flanges of the frames, with the flanges being in mating overlying relationship.

A brief consideration of the above described embodiment will indicate that the invention provides for certain improvements to an air diffuser assembly which are designed to simplify the installation of the assembly, to provide a more aesthetically appealing product, and to substantially reduce the cost of production of the modular core elements in comparison to the arrangement described and illustrated in our Australian Patent 663412.

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Claims (8)

1. An air diffuser assembly of the kind comprising an outer main frame which is formed with walls defining a central downwardly opening recessed section at its lower end, and a plurality of separate modular core elements which are arranged to be housed within said recessed section of the main frame, wherein each core element comprises a square or rectangular peripheral frame supporting a plurality of curved air deflector blades between opposite sides thereof, the improvement wherein the modular core elements are supported by a separate insert frame having a peripheral shape complementary to that of said recessed section, said insert frame comprising outer peripheral frame members and a pair of cross-wise disposed inverted T-shaped inner frame members each extending between respective opposite sides of the insert frame centrally thereof, said inner frame members forming with said outer frame members a 0 plurality of core element receiving pockets or cavities in which the individual core S" 15 elements are loosely seated when in their installed positions, and interlocking means ee** between the insert frame and the main frame for releasably securing the insert frame within said recessed section of the main frame, whereby the core elements can be separately positioned within their respective cavities or pockets so as to provide the selected air delivery pattern, and thereafter the insert frame, along with the core elements, can be inserted upwardly as a sub-assembly into the open lower end of the main frame and snap fittingly located therein. 0: 0,2. An air diffuser assembly according to claim 1 wherein said interlocking means comprise cooperable latch and latch engaging means on the outer peripheral frame members of the insert frame and the walls defining said central recessed section respectively.

3. An air diffuser assembly according to claim 2 wherein said interlocking means comprises a plurality of resiliently deflectable latching tongues or fingers formed in the wall of each said outer frame member, each said tongue or finger having a tooth or projection at or adjacent its upper free end, the teeth or projections on the latching fingers being arranged to latchingly engage within openings or apertures formed in the walls which define said recessed section, when the said insert frame is pushed upwardly thereinto.

4. An air diffuser assembly according to any one of the preceding claims wherein each of the outer frame members of the insert frame is of inverted T-shape wherein the flange of each of the inverted T-shaped inner frame members is slightly greater in width than the width of the bottom flange of each of the outer frame members of the insert frame.

5. An air diffuser assembly according to any one of the preceding claims wherein said outer main frame terminates at its open lower end in an outwardly directed lateral peripheral flange which, when the assembly is fitted into a ceiling, is arranged to firmly bear against the underside surface of the ceiling.

6. An air diffuser assembly according to claim 6 wherein said outwardly directed ;lateral peripheral flange terminates along its inner periphery in a rebate or shoulder for locating the outwardly flanged edges of the outer frame members of the insert frame, whereby when the insert frame is installed, the peripheral flange on the main frame and the outer peripheral flange on the insert frame are approximately flush with one t* another.

7. An air diffuser assembly according to any one of the preceding claims wherein each said modular core element comprises a square frame and a plurality of curved .o °deflector blades each pivotally mounted at its opposite ends in opposite side frame members of the square frame.

8. An air diffuser assembly according to claim 7 further comprising one or two connector bars operatively connected to said deflector blades at one or both ends thereof, whereby the blades are arranged to move simultaneously.

9. An air diffuser assembly substantially as hereinbefore described and with reference to and illustrated in the accompanying drawing. DATED this 291h day of August, 1997 @TRA 7 113 By its Patent Attorneys 4,' MADDERNS O