Automated Self-Sealing Diffuser and Related Method of Use

Abstract

The invention is directed to an automated self-powered HVAC diffuser system having a central control unit that determines room-specific temperature. The system fits within a standard HVAC diffuser through a housing rod having a front side, a rear side and a middle portion. A central rod perpendicularly attached to the front side of the housing rod maintains an expandable damper fan through a damper head. A micro-motor attaches to the expandable damper fan through a drive shaft which expands and contracts the expandable damper fan to regulate conditioned air flowing out of the HVAC diffuser based upon instructions from the central control unit. In addition, a sensory board affixed to the rear end of the housing rod includes an infrared that communicates with the central control unit. A rechargeable battery stores energy, created by an airflow prop rotating through contact with conditioned air, creates electricity via a generator.

Description

FIELD OF THE INVENTION

This invention is directed toward an automated self-sealing diffuser for use in an HVAC system to ensure more efficient and regulated control of temperature within a residential or commercial space.

BACKGROUND OF THE INVENTION

Under normal operating conditions, residential and commercial heating, ventilating and air conditioning (HVAC) systems include a series of ducts to ensure uniform distribution of conditioned air, consistent static pressure and unrestricted air-flow. To assist in this distribution, venting dampers, registers and differs are placed at termination points within the duct system to distribute airflow. Indoor thermostats measure the temperature inside the residential or commercial facility, which will send an electrical signal to the HVAC system. This temperature reading signals the HVAC system to condition the air by heating or cooling it to achieve a desired temperature range.

One key issue with current HVAC systems is that while the duct system is designed to ensure uniform conditioning of air throughout the facility, there are many different factors that lead to large temperature differentials throughout the facility. This can include the sun warming one side of the home or high winds causing cooling a portion of the residence. Sun angles, time of year (seasons), building construction, insulation values (walls & windows), weather conditions, location of structure are also a factor. Further, an addition to an older home or building a home to meet the unique topography of an area may cause uneven cooling or heating despite a high quality and efficient HVAC system.

Another limitation to regulating multiple rooms served by an HVAC system is that each room is not regulated, and there may be only a few zones. Each zone may have a thermostat, which senses the temperature of that particular zone. However, for the same reasons addressed above, this may still lead to temperature swings as each room's temperature within the zone is not monitored. This is occurring while the HVAC system is attempting to satisfy the thermostat within that zone.

The end result of this uneven heating and cooling leads to the overall inefficiency of the HVAC system. This in turn leads to higher electricity costs, larger demands on the HVAC system and a shorter lifespan of the components (and increased replacement costs). In one example, overnight use of an HVAC system may require a zone within the second floor of a home to overheat the first zone on the first floor, to ensure a comfortable sleep environment requiring additional energy expenditure.

There have been several attempts to create electro-mechanical dampers placed within duct systems to better distribute conditioned air through the HVAC system. While these electromechanical dampers help direct air into rooms that require more or less airflow, these dampers are expensive and must be installed when the home is built (or when there is a large renovation). In most cases the added cost for such a system is greater than the savings during the life of the (HVAC) system. In addition, this method is usually very general and not specific to each room or external conditions.

While some wireless methods have been created to assist in damping the various ceiling diffusers within an HVAC system, these require battery operated thermostats rigidly attached to wall registers and ceiling diffusers—which also reduces cost savings. Moreover, while these systems appear to have an advantage, their small battery lives and frequent maintenance make them less practical. More specifically, the life of the batteries are extremely limited due to the thermostat transmitting a radio frequency signal and the receiver and motor section on the damper vent, which continually must be on receiving mode and utilizing motor and armatures to open and close vent.

In other systems, a fan blade or prop is mounted on a small generator in which the air flow within the duct system turns the fan and in turn charges the batteries. This method is an improvement, however, during the seasons of spring and fall when the system is usually dormant or vacation homes in which the system may sit idol for long periods of time, the batteries will deplete to unusable levels rendering the system useless. In addition, these methods are used to limit the airflow to a certain location and not control the entire (HVAC) system or many other factors which effect efficiency.

Current statistics show that some fifty percent of a residential or commercial building expense is the direct result of the HVAC system. As shown above, little progress has been shown to create efficient retrofitted dampeners that will allow improved efficiency of existing duct work in a manner that will actually lead to saving money, energy and resulting fuel. With the growing interest in energy savings, reduction of carbon emissions and increasing energy efficiency—there is a need in the art for an improved damper system to allow more regulated and controlled per-room air heating and cooling.

SUMMARY OF THE INVENTION

This invention is directed to an automated self-powered HVAC diffuser system that can fit into any existing HVAC diffuser. A single HVAC diffuser system may be placed in each room, zone or area to better regulate the temperature throughout a period of time (hours of the day, day, week or month). Each room is equipped with a central control unit, which is supplied energy by an energy supply (a 110V standard plug, by way of example). The central control unit measures room conditions, including temperature and humidity and measures whether they fall within a desired range. The diffuser system may be affixed within the standard HVAC diffuser via a housing rod having a front side, a rear side, and a middle portion. A central hollow rod is perpendicularly attached to the front side of the housing rod proximate the middle portion.

An expandable damper attaches to the central rod via a damper head. The expandable damper comprises an upper frame, a lower frame and bellows. Preferably, the distal ends of the bellows include self-sealing gaskets that contact the walls of the diffuser to reduce the flow of circulated air out of the diffuser. The expandable damper moves about the central rod via a micro-motor, which expands and contracts the expandable damper through a drive shaft to regulate the amount of conditioned air flowing out of the HVAC diffuser based upon instructions from the central control unit.

In addition, a sensory board maybe affixed proximate the rear end of the housing rod proximate the middle portion having an infrared receiver capable of communicating with the central control unit. A generator having an airflow prop creates electricity to supply a rechargeable battery, through rotating the airflow proper due to contact with conditioned air flowing out of the diffuser. The sensory board further comprises an antenna, a circuit board and dip-switches.

Information may be reported from the sensory board through the antenna to an energy management system. The energy management system calculates energy efficiencies and related savings through use of the diffuser system as well as total energy consumption within a home.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the invention, reference is made to the following detailed description, taken in connection with the accompanying drawings illustrating various embodiments of the present invention, in which:

FIG. 1 is a block diagram illustrating salient components of one advanced damper assembly according to the teaching of the present invention;

FIG. 2 illustrates an energy management system;

FIG. 3 illustrates an advanced HVAC damper in an open position;

FIG. 4 illustrates the advanced HVAC damper in a closed position; and

FIG. 5 is a flow chart showing one preferred method of using the diffuser system to increase energy efficiency.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.

This invention helps solve many of the problems of current HVAC systems to ensure more regulated and efficient use of conditioned air. More specifically, embodiments of the invention allow for a retrofitting of traditional HVAC diffusers without requiring an overhaul of existing ducting system. Through the use of wireless and infrared technology, coupled with advanced controls, a quick and efficient instillation of the assembly can be done by any user (not necessarily an HVAC trained professional). The resulting system helps provide a more uniform and controlled circulation, use and enjoyment of conditioned air within each specific room, zone or area of a commercial or residential abode. In addition, the controls are designed to allow different pulls from the central HVAC system, in order to address temperature changes related to sun exposure, topography conditions and the unique layout of the home or office. The end result is more consistent and desired temperatures, less waste of conditioned air (either hot or cold), less energy expenditure and longer life-span of the overall HVAC system.

Overall Components

FIG. 1 illustrates, by way of example, the salient components of the advanced diffuser system 100 contemplated by the invention, for insuring more uniform and regulated per-room distribution of conditioned air. While FIG. 1, illustrates one assembly based upon the teachings of the present invention, one of ordinary skill in the art of HVAC systems will quickly realize other orientations and additional/alternative components that could also be used to allow for more efficient use of HVAC systems without the need to remove or replace the existing ducting work.

As shown, the diffuser system 100 includes a diffuser assembly 110, a central energy management system 200, an energy supply 300, a programmable control unit 400, a hand held control 500 and an infrared receiver 600. The system is both portable and scalable, meaning that additional energy supplies 300, programmable control units and infrared receivers 600 can be placed in multiple zones, rooms, or areas of a residential or commercial facility.

As further shown in FIG. 1, one embodiment of the invention includes an energy supply 200 that provides electricity to a programmable control unit 300. Each energy supply 200 may be connected to a standard electric jack found within the home or commercial facility. This allows the diffuser system 100 to be installed without need of a professional electrician. Likewise, this system eliminates the need for a rewire of a room's electricity.

Preferably, for each zone or room of the home or residential facility desired to be regulated, the invention contemplates placement of a programmable control unit 300 (again powered by an energy supply 200). While the programmable control unit 300 may take various forms, it preferably includes both a temperature and humidity sensor.

Likewise, the programmable control unit 300 should be capable of communicating directly with a hand held controller 500 as well as an infrared receiver 600. If the temperature within the room falls outside a desired range (by either the user, the hand controller 500, or the central energy management system 200), the central control unit 300 will report this information (via the infrared receiver 600) to make changes via the diffuser assembly 110 (open and/or close the diffuser)

As further shown in FIG. 1, the invention contemplates how each zone or room may include a hand controller 500. This hand controller 500 allows the user to physically direct the temperature within that individual room—as well as make changes to that room's temperature during periods of use. This allows for more uniform and regulated per room usage of the HVAC System 290. The hand controller 500 may be placed in a cradle (located on a wall) positioned within each individual room or zone.

As illustrated, the hand controller 500 communicates with the central controller 400, as well as the central energy management system 200 and the infrared receiver 600 (and accordingly the diffuser assembly 110). Preferably, the hand controller 500 includes a receiver, a processor, an internal memory device as well as an internal power supply—which may take the form of a battery.

The Central Energy Management System

The central energy management system 200 shown in FIG. 1 and FIG. 2 represents the core of this energy saving technology. Such system 200 not only communicates with the HVAC system, but also received information from any ancillary devices such as solar panel arrays attached the home's roof, a depository of propane (or a natural gas supply), or a cogeneration system within the home. Such communications allows for a comprehensive energy analysis for the facility, and determines not only energy use across all energy sources, but also determines efficiencies as well as energy savings through using the diffuser system 100.

As shown in FIG. 1, the energy management system 200 communicates directly with each programmable control unit 400, every hand held control 500 and the infrared receiver 600 within each room or area. By directly communicating with the infrared receiver 600, the energy management system 200 thus indirectly communicates with each diffuser assembly 110.

While FIG. 1 illustrates the placement and points of communication with the energy management system 200, FIG. 2 illustrates, by way of example, one specific functionality. As shown, the energy management system 200 communicates with any available solar system panel array 260, propane gas supply 270 and HVAC System 280 accessible by the residential facility or home. This allows for a comprehensive view of the total energy consumption by the home (or facility), as well as the percentage of electricity, gas and solar consumed. As described previously, the energy management system 200 likewise communicates with the diffuser system 100 to ensure proper distribution of conditioned air from the HVA system 280 (or any related co-generation system).

As further shown in FIG. 2, the energy management system 200 includes a touchscreen display 210 which allows a user to access a variety of information relating to overall efficiency of the diffuser system 100, as well as other energy related systems. Such information includes overall energy consumption, peak energy times, and diagnostic data. The touchscreen display 210 also allows the user to program the preferred temperature of each room in which a diffuser assembly 110 is placed—which can be programmed out per hour of day, week or month.

Apart from the touchscreen display 210, the energy management system 200 also includes two display windows 220 and 230. As further shown in FIG. 2, the first display window 220 provides a calculation as to the total dollar figure of energy consumed within a specified time period. Conversely, the second display window 230 reports the total amount of energy (in kilowatts) expended by the residential facility. These calculations are made through a central processor 201, memory unit 202 and internal power supply 203 contained within the energy management system 200.

Optionally, the energy management system 200 may include two or more push bottoms 240 and 250. Both push buttons 240 and 250 select the time period desired to report the total amount of energy consumed, as well as the total costs associated with energy use. For example, by pressing the first push button 240, the first display window 220 will report the total energy savings and/or energy consumer in a dollar figure per day, week month or year. Likewise, employing the second push button 250 shall allow the second display window 230 to report kilowatts, propane pounds (lbs) natural gas expenditures and/or fuel oil used or consumed during a given day, week, month or year.

The invention further contemplates a plurality of various reporting lights 290. These reporting lights 290 illuminate to report if the diffuser system 100 is providing for temperature savings, humidity savings and related metrics.

The Diffuser Assembly

Both FIG. 3 and FIG. 4 illustrate, by way of example, the salient components of one preferred diffuser assembly 110. First turning to FIG. 3, the diffuser assembly 110 fits within the normal shape and configuration of a common HVAC diffuser 111 found within a commercial or residential facility. This allows easy retrofitting of each diffuser 111 within a desired room, zone or area of the home.

This is accomplished by a housing rod 120 that secures directly to the diffuser 111. The housing rod 120 is positioned parallel to the diffuser opening 112. The housing rod 120 includes a first end 121, a second end 122 and a middle portion 123. In addition the housing rod 120 includes a front side 124 and a corresponding rear side 125. A first screw 126 affixes the first end 121 of the housing rod 120 to the diffuser. Correspondingly, a second drew 126 affixes the second end 121 of the housing rod 120. This allows the diffuser system 110 to essentially float within the core of the housing rod 120.

Perpendicularly attached to the front side 124 (proximate the middle portion 123) of the housing rod 120 is a central hollow rod 130. The hollow rod 130 maintains three primary components of the diffuser system 110: the expandable damper fan 140, the micro motor 150 and the drive shaft 160. All three components (140, 150 and 160) work to control the amount and quantity of conditioned air exiting the diffuser 111.

The expandable damper fan 140 functions to open and close the diffuser opening 112. As shown in FIG. 3, the expandable damper fan 130 may include an upper frame 131 and a lower frame 142 that pivot about a damper head 143 affixed to the central hollow rod 130. Positioned between both frames 142 and 143 is a series of bellows 144 suspended about the hollow rod 130 through use of various rivets 145. Positioned at the distal ends 146 of the bellows 144 is a series of self sealing gaskets 147. These self-sealing gaskets 147 help create a contact point 148 between the expandable damper fan 140 and the walls of the diffuser 111.

As further shown in FIG. 3, by pivoting away from the central hollow rod 130 both frames 141 and 142 may contact the outer walls of the diffuser 111 to close the diffuser opening 112. Correspondingly, by contracting the frames 141 and 142 toward the central hollow rod 130 the diffuser 111 is opened to allow the flow of conditioned air outside of the diffuser opening 112. In turn, when expanding the frames 141 and 142 the various rivets 145 maintain the integrity of the bellows 144 to ensure proper closure and opening of the passageway within the diffuser 111 to allow flow of conditioned air.

As shown in FIG. 4, the contraction or expansion of the various frames 141 and 142 of the expandable damper fan 130 is effectuated through use of a micro motor 150 and drive shaft 160. By engaging the micro motor 150 to pull the drive shaft 160 away from the housing rod 120, this will cause the frames 141 and 142 to expand. Likewise, pushing the draft shaft 160 toward the housing rod 120 will cause the frames 141 and 142 to contract.

In addition, the diffuser system 110 also includes various components positioned about the rear side 125 of the housing rod 120. As shown in both FIG. 3 and FIG. 4, there are three primarily components on this side of the housing rod 120: a sensory board 170, a power generator 180 and an airflow prop 190. First, the sensory board 180 preferably includes and houses the infrared receiver 600. Accordingly, the sensory board 180 receives instructions from the hand controller 500, the central controller 400, and potentially the energy management center 200. Preferably, the sensory board 170 may include a power supply 171 in the form of a rechargeable lithium ion (or alternatively a nickel cadmium) battery 172. In addition, the sensory board 170 may include a circuit board 173, an antenna 174 and dip switches 175.

Attached to the sensory board 170 is a generator 180 which helps create electricity to supply power to the battery 172. The generator 180 connects to an airflow prop 190. Through the normal flow of air within the diffuser 111 (when the expandable damper fan 140 is open) the airflow prop 190 will spin, causing rotation within the generator 180 and the creation of electricity. Accordingly, the diffuser system 110 creates its own power through the natural flow of air—without need for rewiring the existing HVAC system 290. Put another way, the generator 180 (via rotation of the airflow prop 190) creates its own electricity to later power the micro motor 150 and drive shaft 160 for purposes of expanding or contracting the expandable damper fan 140.

Method of Use

This invention is further directed to a method of using a diffuser system 110 in combination with the programmable control unit 400, hand controller 500 and the energy management center 200 to improve the efficiency of an existing HVAC system 290. FIG. 5 illustrates, by way of example, one preferred method to employ the diffuser system 100. The method first starts (at 700) by having the central control unit 400 measures (at 710) the temperature and humidity of a particular room or zone. Typically, the central control unit 400 (either directly or through the hand held controller 500) has a pre-set temperature range that is desired for that particular room or zone.

The central control unit 400 next determines (at 720) whether room conditions are within the present range. If such temperature and humidity measures are within range, then the method recycles (to step 710). Otherwise, the method next wirelessly sends (at 740) instructions to the infrared receiver 600 located within the diffuser system 110. Alternatively, a user can manually instruct (at 730) the infrared receiver 600 through the hand held controller 500 in order to change the temperature within the room.

Regardless of whether the central control unit 400 automatically (or if the user manually instructs via the hand held controller 500), the infrared receiver 600 will instruct (at 750) the sensory board 170 to tell the micro motor 180 to engage drive shaft 160. In turn, the drive shaft 160 will contract (at 760) both the upper and lower frames 142 and 143. This will result in reducing the size of the bellows 144 and therefore reducing the cross sectional area of the expandable damper fan 200. This will cause conditioned air to exist (at 770) the diffuser 111 which will in turn cool the desired room, zone or area of the residential or commercial facility for a period of time.

After conditioned air passes through the diffuser 111 to cool or heat the room to a desired temperature, the central control unit 400 will recheck (at 780) the room conditions—including temperature and humidity. The central control unit 400 will recheck (at 785) the temperature and other conditions within the room or area. After making this determination, the central control unit 400 will report this information back to the infrared receiver 600 positioned within the diffuser system 110. If the temperature is still outside of the desired range, the expandable damper fan 200 shall remain open to allow additional conditioned air to pass through the diffuser 111.

However, if the temperature falls within the acceptable range, then the sensory board 170 shall instruct (at 790) the drive shaft 180 to expand both frames 142 and 143 and increase the surface area of the bellows 790. This in turn will cause the energy management center 200 to seal and close off the passage way within the diffuser 111—such that conditioned air will not pass into that room, zone or area. Information is then reported (at 795) to the central energy management system 200—which may in turn calculate energy savings and other efficiencies.

The system may then report (at 710) based upon any preprogrammed temperature profiles within a given day, week or month stored in the central control unit 400.

Claims

1. An automated self-powered HVAC diffuser system comprising:

a central control unit that determines room-specific conditions, including temperature;

a housing rod having a front side, a rear side and a middle portion, wherein the housing rod is dimensioned to be affixed within an opening of a standard HVAC diffuser;

a central rod perpendicularly attached to the front side proximate the middle portion of the housing rod;

an expandable damper fan attached to the central rod through a damper head; and

a micro motor attached to the expandable damper fan through a drive shaft which expands and contracts the expandable damper fan to regulate conditioned air flowing out of the HVAC diffuser based upon instructions from the central control unit.

2. The diffuser system of claim 1, further comprising:

a sensory board affixed proximate the rear end of the housing rod proximate the middle portion, the sensory board including an infrared receiver capable of communicating with the central control unit;

a generator having an airflow prop; and

a rechargeable battery which stores energy created by the airflow prop rotating through contact with conditioned air and creating electricity via the generator.

3. The diffuser system of claim 2, wherein the sensory board further comprises an antenna, a circuit board and dip-switches.

4. The diffuser system of claim 3, further comprising and energy management system wherein information is reported from the sensory board through the antenna to the energy management system.

5. The diffuser system of claim 4, wherein the energy management system calculated energy efficiencies and related savings through use of the diffuser system as well as total energy consumption within a home.

6. The diffuser system of claim 1, wherein the housing rod has a first end and a second end such that the housing rod is affixed to the diffuser opening through a first screw affixed to the first end and a corresponding second screw affixed to the second end.

7. The diffuser system of claim 1, wherein the expandable damper comprises an upper frame, a lower frame and bellows there between.

8. The diffuser system of claim 7, wherein distal ends of the bellows include self-sealing gaskets which contact walls of the diffuser to reduce the flow of circulated air out of the diffuser.

9. An automated self-powered HVAC diffuser system comprising:

a central control unit that determines room-specific conditions, including temperature;

a housing rod having a front side, a rear side and a middle portion, wherein the housing rod is dimensioned to be affixed within an opening of a standard HVAC diffuser;

a central rod perpendicularly attached to the front side proximate the middle portion of the housing rod;

an expandable damper fan attached to the central rod through a damper head;

a micro motor attached to the expandable damper fan through a drive shaft which expands and contracts the expandable damper fan to regulate conditioned air flowing out of the HVAC diffuser based upon instructions from the central control unit;

a sensory board affixed proximate the rear end of the housing rod proximate the middle portion, the sensory board including an infrared receiver capable of communicating with the central control unit;

a generator having an airflow prop operable therewith, the prop rotating through contact with conditioned air and creating electricity via the generator; and

a rechargeable battery which stores energy generated by the airflow prop.

10. The diffuser system of claim 9, wherein the sensory board further comprises an antenna, a circuit board and dip-switches operable therewith.

11. The diffuser system of claim 10, wherein information is reported from the sensory board through the antenna to an energy management system.

12. The diffuser system of claim 11, the energy management system calculated energy efficiencies and related savings through use of the diffuser system as well as total energy consumption within a home.

13. The diffuser system of claim 9, wherein the housing rod has a first end and a second end such that the housing rod is affixed to the diffuser opening through a first screw affixed to the first end and a corresponding second screw affixed to the second end.

14. The diffuser system of claim 9, wherein the expandable damper comprises an upper frame, a lower frame and bellows there between.

15. The diffuser system of claim 14, wherein distal ends of the bellows include self-sealing gaskets which contact walls of the diffuser to reduce the flow of circulated air out of the diffuser.

16. A method of using a diffuser system in combination with a central control unit to improve efficiency of an existing HVAC system, the method comprising the steps of:

(a) measuring a room's temperature through a central control unit;

(b) sending a signal to an infrared receiver within the diffuser system if the room temperature falls outside a desired range;

(c) commanding a micro motor to engage a drive shaft, through instructions received by a sensory board from the infrared receiver, the drive shaft being engaged with an expandable damper fan attached to a central rod through a damper head; wherein the central rod is perpendicularly attached to a housing rod which is affixed to an existing HVAC diffuser; and

(d) constricting the expandable damper fan through the drive shaft in order to allow conditioned air to exist the HVAC diffuser for a period of time in order to change the room temperature.

17. The method of claim 16, further comprising the steps of:

(e) rechecking the room temperature through use of the central control unit;

(f) instructing the drive shaft to expand the expandable damper fan if the room temperature falls within an acceptable temperature;

(g) restricting the flow of conditioned air through the HVAC diffuser; and

(h) reporting information to a central energy management system.

18. The method of claim 17, further comprising the step of:

(i) calculating energy efficiencies and related savings from data reported by the diffuser system to the energy management system, including but not limited to energy savings and total energy consumption within a home.

19. The method of claim 16, wherein the expandable damper comprises an upper frame, a lower frame and bellows attached thereto.

20. The method of claim 19, wherein distal ends of the bellows include self-sealing gaskets which contact walls of the diffuser to reduce the flow of circulated air out of the diffuser.