US20070167127A1

US20070167127A1 - Ventilation air distribution box

Info

Publication number: US20070167127A1
Application number: US11/333,909
Authority: US
Inventors: Robby Wiley
Original assignee: WILEY'S HEATING & AIR Inc
Current assignee: WILEY'S HEATING & AIR Inc
Priority date: 2006-01-17
Filing date: 2006-01-17
Publication date: 2007-07-19

Abstract

An air distribution box for a ventilation air system comprising a housing defining an air passageway between an inlet and a downstream outlet in communication with the ventilation air system. The outlet is defined in an outlet side wall that is positioned at an acute angle with respect to the plane of the inlet such that at least a portion of the outlet faces a portion of the inlet.

Description

FIELD OF THE INVENTION

This invention relates generally to air distribution boxes for use in a forced air ventilation system and, more particularly, to a return air distribution box mountable to the structural elements of the structure for used in such a forced air ventilation system.

BACKGROUND OF THE INVENTION

Convention forced air ventilation systems used in heating and air conditioning system provides central heating or cooling equipment that is connected to a duct system for movement of air within the structure. Typically, the duct system is a branching network of round or rectangular tubes, which are generally constructed of sheet metal, fiberglass board, or a flexible plastic-and-wire composite, that are located within the walls, floors, and ceilings. Preferably, the air ventilation system consists of supply ducts and return ducts. The central heating or cooling equipment (such as, for example, furnace, air conditioner, or heat pump) contains a fan that forces heated or cooled air into supply ducts leading to the rooms. The fan gets its air supply through return ducts.
Typical duct systems lose 10 to 25 percent of the heating or cooling energy put out by the central furnace, heat pump, or air conditioner. Homes with ducts in a protected area such as a basement may lose somewhat less than this, while some other types of systems (such as attic ducts in hot, humid climates) often lose more. Maintaining the integrity of the ducts, in maintenance of the desired interior cross-sectional area of the ducts due to structural compression and/or debris build up, and in minimizing leakage through small cracks and seams in the ducting components can provide a very important energy improvement measure for a structure.
In a conventional air ventilation system, air moves from high pressure to low pressure. To get air to move from the supply duct into the room it serves, the air in the duct has to be at a higher pressure than the air in the room. Similarly, to move air from the room into the return duct, the air in that duct has to be at a lower pressure than the air in the room. The registers are the openings through which this air is intended to move. The fan of the central furnace creates these pressure differences. When the fan stops, these pressures quickly equalize and the flow of air through the duct stops, too. In use, the furnace fan produces a high pressure in the supply ducts and a low pressure in the return ducts. The high pressure forces warm air from the supply ducts to flow into the rooms, and low pressure draws room air back into the return ducts.
An inefficiency is created using conventional return distribution boxes, such as the prior art air distribution box shown in FIGS. 1 and 2. Here, due to the severe bending of the ducting that is required to mate to the upright connection flange of the air distribution box and the limited space available within the opposing trusses of the structure, the cross-sectional area of the return ducting is crimped and restricted, which reduces the efficiency of the air flow between the air distribution box and the central furnace. This inefficiency can cause air leakage into the structure even if neither the supply nor the return ducts leak themselves. This is illustrated in a room that has a supply register and a partially constricted return register. This room will be partially overpressured and air will leak out from the room, which places an added load on the heating equipment.
Thus, there is a need for an air distribution duct that provides for efficient transport of air through the air ventilation system because the amount of heating and air conditioning needed will be much less than in the prior art conventional installation. The air distribution box of the present invention permits the use of a smaller furnace and air conditioner, which require a smaller amount of air flow in the duct system.

SUMMARY

In one embodiment, the air distribution box for a ventilation air system comprises a housing defining an air passageway between an inlet and a downstream outlet in communication with the ventilation air system. In one aspect, the inlet has a peripheral edge formed by the proximal end of the side walls of the housing. In a further aspect, the inlet is positioned in an inlet plane. The outlet of the air distribution box is defined in an outlet side wall that is positioned at an acute angle with respect to the inlet plane such that at least a portion of the outlet faces a portion of the inlet.
Related methods of operation are also provided. Other systems, methods, features, and advantages of the air distribution box for a ventilation air system will be or become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the air distribution box for a ventilation air system, and be protected by the accompanying claims.

DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate certain aspects of the instant invention and together with the description, serve to explain, without limitation, the principles of the invention. Like reference characters used therein indicate like parts throughout the several drawings.
FIG. 1A is a perspective view of a prior art air distribution box that is mountable between truss members of a structure.
FIG. 1B is a side elevational view of the prior art air distribution box of FIG. 1A, showing a partially constricted return duct mounted to the prior art distribution box.
FIG. 2 is a perspective view of a first embodiment of the air distribution box of the present invention.
FIG. 3 is a perspective view of the air distribution box of FIG. 2 mounted between a pair of truss members and connected to a conventional flexible return duct.
FIG. 4 is a side elevational view of an alternative embodiment of the air distribution box of the present invention, showing an elongate air discharge tube that is configured to connect to the proximal end of the return conduit.
FIG. 5 is a side elevational view of the air distribution box of FIG. 2.
FIG. 6 is an exploded view of an air distribution box of the present invention, showing a housing, a grill mountable to the housing, and a filter positionable therein the housing.
FIG. 7 is an assembled cross-sectional view of the air distribution box of FIG. 6, taken across line 7-7 of FIG. 6.

DETAILED DESCRIPTION OF THE INVENTION

The present invention can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present devices, systems, and/or methods are disclosed and described, it is to be understood that this invention is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.
The following description of the invention is provided as an enabling teaching of the invention in its best, currently known embodiment. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the invention described herein, while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present invention are possible and can even be desirable in certain circumstances and are a part of the present invention. Thus, the following description is provided as illustrative of the principles of the present invention and not in limitation thereof.
As used herein, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a “peripheral support member” includes aspects having two or more such peripheral support members unless the context clearly indicates otherwise.
Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.
The present invention may be understood more readily by reference to the following detailed description of preferred embodiments of the invention and the examples included therein and to the Figures and their previous and following description.
In one embodiment, the air distribution box 10 of the present invention comprises a housing 20 for use in a conventional forced air ventilation system. For example and not meant to be limiting, such a conventional air ventilation system can comprise a return conduit 2 for receiving air from a proximal end of the return conduit and subsequently delivering the return air to a central heating/air-conditioning system. In one aspect, the housing 20 is configured to be positioned adjacent to at least one support member 4, such as, for example a truss, of a structure. As one will appreciate, each support member extends a predetermined height dimension D_sbetween a top surface and an opposed bottom surface. For example, a conventional truss can have a 12″ height dimension.
The housing 20 comprises an inlet 22 and a downstream outlet 24 in communication with the return conduit 2 of the air ventilation system. In one aspect, the housing 20 comprises four substantially planar side walls 26 and defines an air passageway 28 extending between the inlet and the outlet. In one aspect, the housing can be formed from sheet metal, a polymer, or the like.
In one example, the inlet 22 of the housing has a peripheral edge 23 that is formed by the proximal ends 27 of the four side walls. In a further aspect, the peripheral edge 23 of the inlet is positioned in an inlet plane 25. In one example, the inlet 22 is substantially co-planar to the bottom surface of the at least one support member 4 when the housing 20 is mounted to the structure. Thus, in this example, the inlet plane 25 can be is substantially parallel to the bottom surface of the respective at least one support member. In a further aspect, the housing 20 has a depth dimension D_hthat is normal to the inlet plane 25 that is less that the height dimension of the at least one support member. Thus, in the example of a 12″ truss, the housing 20 has an overall height that is less than the height dimension of the truss.
In a further aspect, the outlet 24 of the housing is defined in an outlet side wall 30 of the four side walls of the housing. The outlet side wall 30 is positioned at an acute angle θ with respect to the inlet plane 25 such that at least a portion of the outlet faces a portion of the inlet 22. Accordingly, in one aspect, the acute angle θ can have a range of from between about 5 to 85 degrees, which includes exemplary angles of 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, and 80 degree.
In one example, the housing further comprises a top wall 32 that is connected to the distal ends 29 of the four side walls. In this aspect, the top wall 32 is spaced a predetermined distance D_hfrom the inlet of the housing. As one will appreciate, the top wall is spaced from the inlet a dimension that is less than the height dimension of the structural member to which it is mounted for support.
Referring to FIGS. 3 and 5, in one example, the housing of the air distribution box 10 of the present invention has a trapezoidal cross-sectional shape. In this example, the top wall 32 of the housing 20 is substantially parallel to the inlet plane. In one example of this aspect, the trapezoidal cross-sectional shape of the housing 20 forms an isosceles trapezoid shape.
In another aspect, the housing 20 further comprises a mounting flange 40 that extends outwardly therefrom at least a portion of the peripheral edge 23 of the inlet 22 substantially co-planer to the inlet plane 25. In use, at least a portion of the mounting flange 40 can be used to mount the housing 20 to the at least one support member 4. Alternatively, at least one mount member 8 can be used to span an opposing pair of support members 4 and at least a portion of the mounting flange 40 of the housing 20 can be mounted thereto the at least one mount member. In one exemplary aspect, the mount member has a lip 9 that is folded over to form a slot that is configured for receipt of the mounting flange 40 of the housing. In this aspect, it is contemplated that, while the mount members are fixed to the respective support members, the housing can me moved or slid longitudinally along the elongate lengths of the respective mount members into a desired position relative to the mount members.
In another aspect, the housing 20 further comprises a collar 44 that extends outwardly therefrom at least a portion of a peripheral edge 45 of the outlet 24 substantially normal to the outlet side wall 30. In this example, the collar 44 is configured to mount to conventional duct tubing, such as, for example, the proximal end of a flexible return conduit 4.
In an alternative embodiment shown in FIG. 6, the outlet 24 of the housing 20 comprises an elongate discharge tube 46. In this aspect, the distal end 48 of the discharge tube 46 is configured to connect to the proximal end of the return conduit 4. In a further aspect, the discharge tube 46 can extend substantially parallel to the inlet plane 25 so that the distance between the housing's top wall and inlet remain the maximum height dimension of the housing 20.
In a further aspect of the invention, the housing can further comprise a shoulder member 47 that extends outwardly therefrom the peripheral edge 23 of the inlet away from the inlet plane 25 of the housing. In one aspect, the shoulder member substantially surrounds the inlet 22 of the housing. Alternatively, the shoulder member can extend therefrom at least a portion of the peripheral edge of the inlet. In another aspect, the shoulder member 47 extends outwardly from the peripheral edge of the inlet substantially transverse to the inlet plane 25.
Turning to FIGS. 7 and 8, an alternative embodiment of the air distribution box 10 of the present invention is illustrated. In one aspect of this embodiment, the air distribution box further comprises a grill 50 that, in one exemplary aspect, is attachable to the mounting flange 40 of the housing 20 and configured to overlie the inlet 22 of the housing. The grill 50 can be attached to the mounting flange 40 by conventional fasteners 52, such as and not meant to be limiting, screws, bolts, clips, and the like. It is contemplated that the grill can be releaseably mounted to the mounting flange or fixedly mounted to the mounting flange.
In a further aspect, the air distribution box 10 of the present invention can comprise a filter 60 positionable between the mounting flange 40 of the housing and the grill 50. In this aspect, the grill forms a circumferentially extending and inwardly facing trough 54 configured to accept a shoulder member 62 of the filter. A suitable grill 50 is one manufactured by Barnett, model number 19FG-16X25W, it being understood that other grills are acceptable so long as they can hold and transmit the desired filter.
In another aspect, the filter 60 is configured to extend therein the housing 20 a predetermined distance. For example, the filter can be configured such that the respective sides 64 of the filter 60 are positioned proximate a portion of the four side walls 26 of the housing 20. Alternatively, the filter 60 can be configured such that at least a portion of the respective sides 64 of the filter are in contact with a portion of the interior surface of the housing. In a further aspect, at least a portion of the housing 20 proximate the inlet 22 can be configured to seat the filter and/or at least a portion of the grill. For example and not meant to be limiting, at least a portion of the inlet portion of the housing can be configured to receive at least a portion of a generally rectangular filter therein the interior volume of the housing. One will appreciate that conventional filters, such as, for example and not meant to be limiting, ones manufactured by Honeywell International or by Purolator® Air Filtration, it being understood that other conventional filters are acceptable so long as they are mountable within the inlet portion of the housing 20.
The preceding description of the invention is provided as an enabling teaching of the invention in its best, currently known embodiment. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the invention described herein, while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present invention are possible and can even be desirable in certain circumstances and are a part of the present invention. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. Thus, the preceding description is provided as illustrative of the principles of the present invention and not in limitation thereof. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.

Claims

1. An air distribution box for a ventilation air system of the type that includes a return conduit for receiving air from a proximal end of the return conduit and for positioning adjacent at least one support member of a building, each support member extending a predetermined height dimension between a top surface and an opposed bottom surface, comprising:

a housing having an inlet and a downstream outlet in communication with the return conduit, the housing comprising four substantially planar side walls and defining an air passageway between the inlet and the outlet, wherein the inlet has a peripheral edge formed by the proximal ends of the four side walls that is positioned in an inlet plane, and wherein the outlet is defined in an outlet side wall of the four side walls of the housing, the outlet side wall being positioned at an acute angle with respect to the inlet plane such that at least a portion of the outlet faces a portion of the inlet.

2. The air distribution box of claim 1, wherein the inlet plane is substantially parallel to the bottom surface of the respective at least one support member, and wherein the housing has a depth dimension normal to the inlet plane that is less that the height dimension of the at least one support member.

3. The air distribution box of claim 1, wherein the housing is formed from sheet metal.

4. The air distribution box of claim 1, wherein the housing comprises a top wall that is connected to the distal ends of the four side walls, the top wall being spaced a predetermined distance from the inlet of the housing.

5. The air distribution box of claim 4, wherein the housing has a trapezoidal cross-sectional shape, and wherein the top wall is substantially parallel to the inlet plane.

6. The air distribution box of claim 5, wherein the trapezoidal cross-sectional shape forms an isosceles trapezoid shape.

7. The air distribution box of claim 1, wherein the housing further comprises a mounting flange that extends outwardly therefrom at least a portion of the peripheral edge of the inlet substantially co-planer to the inlet plane.

8. The air distribution box of claim 1, wherein the housing further comprises a collar that extends outwardly therefrom at least a portion of a peripheral edge of the outlet substantially normal to the outlet side wall.

9. The air distribution box of claim 1, wherein the acute angle is less than about 75°.

10. The air distribution box of claim 1, wherein the acute angle is less than about 60°.

11. The air distribution box of claim 1, wherein the acute angle is less than about 45°.

12. The air distribution box of claim 1, wherein outlet of the housing further comprises an elongate air discharge tube extending substantially parallel to the inlet plane, the distal end of the air discharge tube configured to connect to the proximal end of the return conduit.

13. The air distribution box of claim 7, further comprising a grill releasably attachable to the mounting flange of the housing and configured to overlie the inlet of the housing.

14. The air distribution box of claim 13, further comprising a filter positionable between the mounting flange of the housing and the grill.

15. The air distribution box of claim 14, wherein the grill forms a circumferentially extending and inwardly facing trough configured to accept a shoulder member of the filter.

16. The air distribution box of claim 15, wherein the filter is configured to extend therein the housing a predetermined distance and is configured such that the respective sides of the filter are positioned proximate a portion of the four side walls of the housing.

17. An air distribution box for a ventilation air system of the type that includes a return conduit for receiving air from a proximal end of the return conduit and for positioning adjacent at least one support member of a building, each support member extending a predetermined height dimension between a top surface and an opposed bottom surface, comprising:

a housing having an inlet and a downstream outlet in communication with the return conduit, the housing defining an air passageway between the inlet and the outlet, the inlet being positioned in an inlet plane and the outlet being defined in an outlet side wall of the housing, the outlet side wall being positioned at an acute angle with respect to the inlet plane such that at least a portion of the outlet faces a portion of the inlet, wherein the housing further comprises a mounting flange that extends outwardly therefrom the inlet substantially co-planer to the inlet plane;

a grill configured to overlie the inlet of the housing; and

a filter positionable therein a portion of the air passageway proximate the inlet of the housing, wherein the filter underlies the grill.

18. The air distribution box of claim 17, wherein the grill forms a circumferentially extending and inwardly facing trough configured to accept a shoulder member of the filter.

19. The air distribution box of claim 17, wherein the filter is configured to extend therein the air passageway of the housing a predetermined distance and is configured such that at least a portion of a peripheral exterior surface of the filter is positioned proximate a portion of an interior surface of the housing.

20. The air distribution box of claim 17, wherein the inlet plane is substantially parallel to the bottom surface of the respective at least one support member, and wherein the housing has a depth dimension normal to the inlet plane that is less that the height dimension of the at least one support member.