AU740570B2 - Improvements in and relating to air diffuser grilles - Google Patents

Description

Regulation 3.2

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

a Name of Applicant: Actual Inventor: Address for Service: Invention title: K-Aire Pty Ltd Andrew Rogers MADDERNS, 1st Floor, 64 Hindmarsh Square, Adelaide, South Australia, Australia IMPROVEMENTS IN AND RELATING TO AIR DIFFUSER

GRILLES

Details of Associated Provisional Application No: PP 2167 dated 5th March 1998 The following statement is a full description of this invention, including the best method of performing it known to us.

This invention relates to an improved air diffuser outlet grille assembly which is arranged to be mounted in a ceiling and through which air discharges into a space to be ventilated.

Two types of air diffusers or outlet grilles are well known and commonly used in the air conditioning industry. One known type employs removable modular core elements with adjustable blades. These allow the direction and volume of air distribution to be altered, either by adjusting the positions of the blades of the modular core elements, or by altering the orientation of the individual elements relative to another. The diffuser can thus be adjusted for optimum delivery of air into any particular room or other space.

o The other type has a "fixed" construction and comprises a series of concentric oooo rectangular metal frame portions each of which is rigidly secured, by welding, to a 15 metal mounting frame located above the frame portions, the frame portions defining blades or vanes with air passages therebetween through which air can flow.

Conventionally, the blades or vanes have always been formed as planar members.

While air diffusers of the second type have been generally satisfactory, they do 20 possess certain disadvantages particularly from the point of view of economy of manufacture in that each different size diffuser requires separate tooling to manufacture. Their fixed construction deprives them of versatility and prevents the removal of the blades or vanes.

It is the main object of the present invention to provide improvements in and to air diffuser assemblies for use in conjunction with air conditioning/ventilating systems, which will allow the vanes/blades to be readily assembled with and disassembled from a supporting frame, and at the same time permit the supporting frame and the vanes/blades to be manufactured and assembled in an economical manner.

It is a further object of the present invention to provide an improved air diffuser assembly having a supporting frame which can be produced in a variety of sizes from a single die.

Broadly according to this invention therefore, an air diffuser assembly for use adjacent an outlet of a ventilating/air conditioning system comprises: an integrally formed skeletal framework having a plurality of first frame members extending outwardly from a centre region of the framework and a plurality of second frame members intersecting said first frame members, a plurality of sets of vanes or blades arranged in a pattern on the air discharge side of the framework, with the blades or vanes of each said set being in spaced parallel relationship with air passages therebetween through which air can flow, and 9**o releasable attachment means for relasably attaching each of the vanes or So° blades of respective said sets to at least two of said first frame members.

9 More specifically, an air diffuser assembly according to this invention comprises: •an integral supporting skeletal framework which itself comprises a plurality of concentric rectangular, mutually spaced apart frames each having interconnected peripheral frame members, and a pair of diagonal frame members extending diagonally through the concentric rectangular frames and respectively interconnecting the diagonally aligned corners of said rectangular frames to one another, a plurality of sets of vanes or blades with the blades/vanes of each set being in spaced parallel relationship and forming a triangular array, there being four such triangular arrays of said vanes/blades, and releasable attachment means for releasably securing each of the vanes/blades to said diagonal frame members to thereby form the complete diffuser assembly.

Preferably, the attachment means comprise co-operable snap-fitting connections formed by at least two spigot formations at or adjacent opposite ends of each of the blades, and socket formations integrally formed with said diagonal frame members for snap-fittingly receiving said spigot formations.

Preferably each of the vanes/blades has a curved cross-sectional shape.

Desirably, the ends of adjacent blades of adjacent blade sets are in contiguous or near contiguous relationship.

Desirably, the peripheral frame members of the outermost rectangular frame are formed with projections on the outer surfaces thereof, and which allow the assembled diffuser to snap-fittingly engage within a rectangular outer support frame, said outer support frame being adapted for connection to a neck adaptor frame which in turn connects to a duct line of the ventilation/air conditioning system.

g Desirably, the supporting framework also comprises a pair of perpendicularly oooo oo:. 15 intersecting stiffening frame members which pass through the centre of the 15 rectangular framework and which intercept the peripheral frame members of the respective rectangular frames at right angles. These additional frame members will normally be required for relatively large diffuser assemblies so as to provide additional rigidity. Socket formations can also be formed on these additional frame members to permit the individual blades/vanes to be releasably attached thereto as 20 well as to the diagonal frame members. Preferably, the framework of the diffuser assembly is integrally formed as a planar moulding.

With the diffuser assembly of this invention, the supporting framework can be moulded from a single die regardless of its size. This is achieved by forming a die with a plurality of separate rectangular channels, each having its own inlet tap or valve which controls the flow of molten material into the channel, each of the rectangular channels being shaped to form a respective said rectangular frame of the supporting framework. Consequently the size of the supporting framework can be controlled by simply closing off certain ones of the valves/taps to prevent molten plastics material flowing into those channels. This enables air diffusers of different sizes to be manufactured at economic advantage.

In order to further explain the present invention, a preferred embodiment thereof is described hereunder in some further detail with reference to and illustrated in the accompanying drawings wherein: Fig 1 is a partly exploded perspective view of an air diffuser assembly (showing one of the vanes detached from the framework) produced in accordance with the present invention; Fig 2 is a view similar to Fig 1 showing the supporting framework of the assembly with all but one of the vanes/blades removed therefrom; Fig 3 is a vertical section view of a complete air conditioning outlet system which has the air diffuser assembly fitted thereto, adapted for connection to a duct of the air conditioning system; and ***Fig 4 is a fragmentary enlarged perspective view of the snap-fit connection for oooo each of the blades.

15 Referring to Figs 1 and 2 of the accompanying drawings, an air diffuser assembly comprises an integrally moulded plastics, inner skeletal supporting framework 11 having a square peripheral shape and a plurality of sets of elongated air directing vanes or blades 12 on the air discharge side of the framework 11, each set of blades being arranged in a triangular array with the blades of each set being in spaced 20 parallel relationship and defining therebetween air flow passages. In this embodiment each of the blades 12 has a curved cross-sectional profile for improving the flow pattern of air discharging from the diffuser into a room being ventilated.

The skeletal supporting framework 11 comprises a series of concentric rectangular spaced apart co-planar frame portions 14 which are interconnected by means of a pair of diagonally extending connector frame members 15, 16 which extend between respective pairs of opposite corners of the framework 11 and by a pair of cruciform connector frame members 17, 18 which extend perpendicularly between respective pairs of opposite sides of the framework 11. In some cases where the size of the diffuser is relatively small, the connector frame members 17, 18 can possibly be omitted (as could also the inner ones of the frames 14). For larger size diffusers, however, the connector frame members 15, 16, 17, 18 are necessary for strength purposes and to ensure that the concentric frames 14, especially the larger outer frames, are firmly supported and sufficiently stiffened.

Each of the frame members 15-18 is provided with a plurality of evenly spaced apart socket formations 20 spaced along the length thereof, the socket formations 20 being arranged in aligned pairs on opposite sides of the frame members 15, 16, while for each of the frame members 17,18, the sockets 20 are formed on one side only between the centre point C and its outer end (refer Fig. The socket formations on the diagonal frame members 15, 16 are 'desirably' located at or adjacent the corner regions of each of the rectangular frames 14.

S The blades 12 are provided with integrally formed outwardly projecting, o*o.

engagement spigots or pins 22 which releasably clip into respective socket .ooo formations 20 on the frame members of the supporting framework 11. In this 15 embodiment each blade 12 is provided with three such spigots 22. Each spigot 22 is of bifurcate design and comprises a pair of spaced apart opposed limbs 22' and 22" which terminate at their free ends in enlarged projections 23, the limbs 22', 22" being resiliently deflectable towards one another when the spigot 22 is press fitted into its associated socket formation 20 (refer Fig. 4).

As shown in Fig 2 of the drawings, the peripheral frame members of each of the rectangular frames 14 are provided with outwardly projecting protrusions or nibs These are used to retain the diffuser assembly 10 within a rectangular outer frame (refer Fig 3) which has a square recessed section which opens downwardly to enable the air diffuser 10 to be pushed upwardly thereinto. The outer frame 30 has a perimeter wall 31 in which is formed a plurality of apertures 32 which co-operate with the protrusions 25 to form a snap-fitting engagement between the frame 30 and the assembled air diffuser The outer frame 30 joins to a neck adaptor frame or housing 34 which is adapted to connect to an air supply duct (not shown) from which air is delivered to the diffuser assembly 10 and into the room or space which is being conditioned.

In the assembly of the air diffuser 10, the individual moulded plastics blades 12 are fitted to the moulded supporting framework 11 with the adjacent blades of adjacent sets having their end faces in contiguous or near contiguous relationship. The number of rectangular frames 14 is determined by the size of the air diffuser which is required and this in turn governs the number of individual blades 12 which are required to be fitted to the framework 11.

As shown in Fig 1, the centre C of the diffuser 100 can have snap-fitted thereto a central solid square moulding 36 which is profiled to have curved sides 37 which form blades which are parallel with and spaced from the innermost blades 12 so as to form air flow passages therebetween. The moulding 35 is similarly provided with a spigot 38 which snap-engages with a socket formed at centre C of the framework 11.

A single die can be used to produce the supporting framework 11 in a number of 15 different sizes. This is achieved by using a gating system which incorporates a series of individual taps or valves which can be used to control the flow of molten plastics material into a series of rectangular channels formed in the die and which form the actual frames 14. By closing off some of those valves or taps (associated with the channels in the outer region of the die), the size of the moulded framework 11 can be readily varied.

It will be appreciated that the means by which the blades or vanes 12 are releasably attached to their supporting framework 11 can be achieved in a number of different ways and need not be limited to the form of snap-fitting disclosed herein.

Furthermore, the actual configuration of the supporting framework 11 may also vary in such a way that the blades 12 do not have to be arranged in four triangular arrays so as to form a rectangle.

A brief consideration of the abovedescribed embodiment will indicate that the invention provides for a vastly improved air diffuser assembly having greatly increased versatility in that it allows diffusers of different sizes to be manufactured in a highly cost effective manner and easily and quickly assembled.

Claims (16)

1. An air diffuser assembly for use adjacent an outlet of a ventilating/air conditioning system comprising: an integrally formed inner skeletal framework having a plurality of first frame members extending outwardly from a centre region of the framework and a plurality of second frame members intersecting said first frame members, a plurality of sets of vanes or blades arranged in a pattern on the air discharge side of the framework, with the blades or vanes of each said set being in spaced parallel relationship so as to form air passages therebetween through which air can flow, and releasable attachment means for relasably securing each of the vanes or blades of respective said sets to at least two of said first frame members of said framework.

2. An air diffuser assembly according to claim 1 wherein said first frame i 15 members comprise a pair of diagonal members which extend diagonally across the framework and extend between respective pairs of opposite corners thereof.

3. An air diffuser assembly according to claim 2 wherein said first frame members further comprise a pair of perpendicularly intersecting stiffening frame 20 members which pass through the centre of the framework and which intercept said second frame members at right angles.

4. An air diffuser assembly according to either claim 2 or claim 3 wherein said second frame members form a plurality of concentric rectangular mutually spaced apart frames, said pair of diagonal frame members extending diagonally through the rectangular frames and respectively interconnecting the diagonally aligned corners thereof to one another.

An air diffuser assembly according to any one of the preceding claims wherein said attachment means comprise co-operable snap-fitting connections between said blades or vanes and said first frame members thereby enabling the blades to be attached to the framework.

6. An air diffuser assembly according to claim 5 wherein said snap-fitting connections are formed by at least two spigot formations at or adjacent opposite ends of each of the blades, and socket formations integrally formed with said diagonal frame members for snap-fittingly receiving said spigot formations.

7. An air diffuser assembly according to any one of the preceding claims wherein each said vane or blade has a curved cross-sectional shape.

8. An air diffuser assembly according to any one of the preceding claims wherein the peripheral frame members of the outermost rectangular frame are formed with projections on their outer surfaces, and which allow the assembled diffuser to snap- .9.9 fittingly engage within a rectangular outer support frame, said outer support frame o. being adapted for connection to a neck adaptor frame which in turn is connectable to 15 a duct line of the ventilation/air conditioning system.

9. An air diffuser assembly according to any one of the preceding claims wherein said skeletal framework is planar. 99920

10. An air diffuser assembly for use adjacent an outlet of a ventilating/air conditioning system comprising: 9 ~an integrally formed supporting framework which has a plurality of concentric rectangular mutually spaced apart frame portions, each said frame portion comprising peripheral frame members, and a pair of diagonal frame members extending diagonally through said concentric rectangular frame portions and respectively interconnecting the diagonally aligned corners of said rectangular frame portions to one another, a plurality of vanes or blades each individually attachable to said framework on its air discharge side so as to form four triangular blade sets with the vanes or blades in each set being in spaced parallel relationship, and forming air flow passages therebetween, and co-operable snap-fitting connections between each of the blades or vanes and said diagonal frame members thereby enabling the blades or vanes to be releasably secured to said framework to thereby form the complete diffuser assembly.

11. An air diffuser assembly according to claim 10 wherein said co-operable snap- fitting connections comprise at least two spigot formations at or adjacent opposite ends of each of the blades, and socket formations integrally formed with said diagonal frame members for snap-fittingly receiving said spigot formations.

12. An air diffuser assembly according to claim 10 or claim 11 wherein said supporting framework further comprises a pair of perpendicularly intersecting stiffening frame members which pass through the centre of said framework and which intercept said peripheral frame members of the rectangular frame portions at right angles. 1

13. An air diffuser assembly according to claim 12 wherein said stiffening frame members are provided with socket formations to permit the individual blades or ••0o@ vanes to be releasably snap-fitted thereto. S.0000 S 20

14. An air diffuser assembly according to any one of the preceding claims wherein said skeletal supporting framework is a planar plastics moulding.

An air diffuser assembly according to any one of the preceding claims wherein adjacent blades of adjacent said sets have their ends in contiguous or near contiguous relationships.

16. An air diffuser assembly substantially as hereinbefore described with reference to and illustrated in the accompanying drawings. Dated this 5th day of March, 1999. K-AIRE PTY LTD By its t Attorneys MAI