RELATED APPLICATIONS This application is a continuation-in-part of the co-pending application Ser. No. 10/353,693, filed on Jan. 28, 2003, which itself is a continuation-in-part of application Ser. No. 09/761,145 filed on Jan. 16, 2001 and issued as U.S. Pat. No. 6,511,373, which are incorporated in their entirety herein by reference.
FIELD OF THE INVENTION The present invention is directed to a heating, ventilating, and air conditioning duct system and, more particularly, to a duct system located in the conditioned space of a building for distributing heated or cooled air and having an aesthetically pleasing appearance.
BACKGROUND OF THE INVENTION Traditional air distribution systems include duct work that extends between an air handling unit and a conditioned room space. Conditioned room space is the space occupied by persons within a building in which air may be heated, cooled, or otherwise conditioned. The duct work extends along the exterior, non-conditioned space between interior walls, above the ceiling, or below the floor such that it is not visible to a viewer. Approximately 25-40% of the energy (heating or cooling capacity) in ordinary air distribution systems is lost to duct leakage and heat conduction through duct walls. As energy becomes a more treasured commodity and as energy costs climb higher, methods for reducing these losses are becoming more important.
In a few modern architectural projects, the duct work has been exposed within the interior conditioned space by using utilitarian ducts suspended from the ceiling. Although energy efficient and acceptable in large open commercial and institutional spaces, this technique is not applicable to most intimate spaces such as smaller offices and residences, especially those having a more traditional designed environment. Additionally, exposed duct work may not be effective in distributing air. Often, the ducts distribute air through a limited number of outlet vents causing localized drafts that are very disruptive to the comfort zone of a space. In other situations, the conditioned air tends to stratify and not reach the occupancy zone of the space.
SUMMARY OF THE INVENTION The present invention is directed to an air distribution system that has an aesthetically pleasing appearance and functionally distributes conditioned air throughout a room, plurality of rooms, or an entire building. The distribution system is positioned within the conditioned space such that any air leakage or heat conduction occurs within the conditioned space and is not wasted or lost, thus providing a more energy efficient air distribution system.
BRIEF DESCRIPTION OF THE DRAWINGSFIG. 1 is a partial perspective view illustrating an air distribution network constructed according to one embodiment of the present invention;
FIG. 2 is a cross-sectional view of a duct constructed according to one embodiment of the present invention;
FIG. 3A is a cut-away perspective view of a junction box having a baffle and an attached duct;
FIG. 3B is a partial schematic view of a junction box having a fan;
FIG. 3C is a partial schematic view of a junction box having a heat exchanger;
FIG. 3D is a partial schematic view of a junction box having a damper;
FIG. 3E is a partial schematic view of a junction box having turning vanes;
FIG. 3F is a partial schematic view of a junction box having a filter;
FIG. 4 is a schematic plan view of an air distribution network placed along the interior walls of a conditioned space;
FIG. 5 is a cross-sectional view of the duct constructed in accordance with one embodiment of the present invention;
FIG. 6 is a cross-sectional view of one embodiment of a duct constructed according to the present invention;
FIG. 7 is a cross-sectional view of one embodiment of a duct constructed according to the present invention;
FIG. 8 is a cross-sectional view of one embodiment of a duct constructed according to the present invention;
FIG. 9 is a cross-sectional view of one embodiment of a duct constructed according to the present invention;
FIG. 10 is a schematic plan view of an air distribution network placed along the interior walls of a conditioned space;
FIG. 11 is a cross-sectional view of one embodiment illustrating a duct, a hanger, and a panel;
FIG. 12 is a cross-sectional view of another embodiment illustrating a duct, a hanger, and a panel;
FIG. 13 is a cross-sectional view of another embodiment illustrating a duct, a hanger, and a panel;
FIG. 14 is a schematic view of a joining insert connecting two ducts according to one embodiment of the present invention; and
FIG. 15 is a schematic view of a corner unit, joining inserts, and ducts according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION The present invention is directed to an air distribution network, generally designated10 inFIGS. 1, and4, located in the conditioned space with the purpose of distributing conditioned air. Conditioned air is air that has been heated, cooled, humidified, filtered, or otherwise treated. A series ofducts20 extend along the walls of the conditioned space for conducting and directing the air. Theducts20 include outlets28 (FIG. 2), which distribute the air evenly throughout the conditioned space. Junction boxes30 (FIG. 1) are located about the space and connect theducts20 forming thedistribution network10.Junction boxes30 may further include air-controlling devices for further distributing the air. Conditioned air is introduced into the air distribution network through at least one of thejunction boxes30. The conditioned air is conducted through theducts20 and passes through theoutlets28 into the conditioned space.
FIG. 1 illustrates a section of thedistribution network10.Junction box30 is positioned within a corner of the room and connects twoseparate ducts20. In one embodiment, the exterior surface of theducts20 and/orjunction box30 are ornamentally decorated thereby enhancing the appearance of the room. Thedistribution network10 serves both the functional purpose of distributing air throughout the room while also providing an aesthetically pleasing appearance.
FIG. 2 illustrates a cross-sectional view of theduct20.Ornamental surface22 extends around a portion of theduct20 that is visible to a viewer positioned in the conditioned space when thedistribution network10 is mounted.Ornamental surface22 may have a variety of designs giving the impression that theduct20 is a decorative molding. As illustrated inFIG. 2,ornamental surface22 comprises the surfaces that extend along the bottom and front side of theduct20, e.g. front and bottom surfaces. Various ornamentation and designs are contemplated and are to be included within the scope of the present invention. In the disclosed embodiments, the front surface has a form reminiscent of a segment of crown molding. The bottom surface is illustrated and described as plain but does not detract from the appearance of theduct20. Bottom surface may, however, contain additional ornamentation. Mountingsurface24, e.g. the back wall of the duct, abuts against the interior wall of the conditioned space. An upper wall having anupper surface25 may also be substantially flat for mounting against the ceiling, or supporting an array of items such as luminaries that indirectly light the conditioned space when thetop surface25 is positioned away from the ceiling. Additionally,top surface25 may include a cable tray for holding items including telephone lines, electrical cables, data cables, fiber-optic cables, and the like such that they are not visible to a person within the conditioned space. Additionally, mirrored surfaces may be placed along the walls and ceiling to direct the light as necessary. Although the shape illustrated inFIG. 2 is substantially rectangular, other shapes and embodiments are also contemplated by the present invention.
At least onerecess26 may be formed in theduct20 for hiding anoutlet28 andflow control mechanism29.Outlet28 is an opening to the duct interior through which air is diffused into the conditioned space.Flow control mechanism29 extends over theoutlet28 and controls the flow rate of air being distributed.Ornamental surface22 may form aprojection27 adjacent to therecess26 such that therecess26 is not easily visible by a viewer. As viewed inFIG. 1, the recesses are not easily visible by a person positioned within the occupancy zone of the room. By not being easily visible, recesses26 andoutlet28 do not detract from the aesthetic appearance of thedistribution network10.
In one embodiment as illustrated inFIG. 2, a pair ofrecesses26 andoutlets28 are formed in theduct20, one at the intersection of the top wall and front wall of theduct20 and one at the intersection of the back wall and bottom wall of theduct20.Recesses26 andoutlets28 are positioned such that air is directed along the ceilings and/or walls of the conditioned space. This positioning causes the air to migrate along the ceiling and/or wall surface to create a blanket of supply air that tends to offset the energy loads incurred by walls and windows, especially during the heating season, and energy loads from the ceiling during the cooling season. This position is also advantageous in that it creates a projected air pattern that is outside the occupancy zone of the space.
Theflow control mechanism29 may be positioned over theoutlet28 to control the direction and volume of air directed from theduct20 into the conditioned space. One example of a flow control mechanism is a diffuser strip positioned over theoutlets28. The diffuser strip includes a plurality of orifices that overlay theoutlets28 and are adjustable to control the size of an opening through which air is directed. Theflow control mechanism29 may be manually adjustable such that a user may adjust the openings, or may be controlled by a remotely controllable device having a stepper motor which is especially convenient when thedistribution network10 is positioned within the upper reaches of the room and not easily accessible.
Ducts20 have either a one-piece construction or a multi-piece construction. Either type construction provides for straight-forward installation as the duct ends are slipped into corresponding openings within thejunction boxes30 to complete thenetwork10.Ducts20 andjunction boxes30 may be constructed from a variety of materials.Junction boxes30 are selectively positioned throughout thedistribution network10.Openings32 in thejunction boxes30 are sized and shaped to correspond to the cross-section of theducts20 are positioned on at least one side of thejunction boxes30 for receiving and supportingducts20. In one embodiment,openings32 are sized such thatduct20 fits snugly within theopening32 thereby limiting air leakage that occurs at the connection. Caulk or insulation may also be inserted within any gaps between theduct20 andjunction box30 to further reduce air leakage.Exterior surface36 contains a complementary ornamental design to complement the ductornamental surface22 for an aesthetically pleasing appearance for a viewer. As illustrated inFIG. 1, exteriorornamental surfaces36 may include a bottom surface, and side walls through whichducts20 extend.
As illustrated inFIG. 3A, mountingsurfaces37 are substantially flat such that they may be positioned against the wall of the conditioned space.Top surface38 may likewise be flat and be positioned against the ceiling, or may be equipped with lights or other decorative motif depending on the desires of the user.
Air flow controllers may be positioned within one or more of thejunction boxes30 for directing or controlling the air flow through thedistribution network10. A variety of air flow controllers may be positioned within the network including: abaffle50 for directing air into theducts20 as illustrated inFIG. 3A; abooster fan51 for assisting the air handler and moving the air throughout thedistribution network10 as illustrated inFIG. 3B; aheat exchanger52 as illustrated inFIG. 3C; adamper53 for opening andclosing ducts20 within the network illustrated inFIG. 3D; aflow director54 such as radiused corner bends and/or turning vanes to enhance air directional changes illustrated inFIG. 3E; and afilter55 illustrated inFIG. 3F. Other air flow controllers may further be included and are within the scope of the present invention.
Junction boxes30 may be positioned within the corners of the space resulting in directional changes in thedistribution network10, or may be positioned along a substantially linear section of theduct20. In one embodiment,junction boxes30 include mounting mechanisms for attaching to the wall of the conditioned space for supporting thedistribution network10.Holes31, as illustrated inFIG. 3A, positioned along the mountingsurfaces37 are sized for fastening devices such as screws and the like for securing thejunction boxes30 to the walls.Ducts20 are then inserted within theopenings32 and thereby supported by thejunction boxes30 without themselves being directly secured to the room walls. Openings (not illustrated) within theduct mounting surfaces24 may be available for further mounting theducts20 to the wall of the conditioned space.
Thedistribution network10 may be positioned at a variety of heights along the wall of the conditioned space. In one embodiment, the junction boxtop surface38 and ducttop surface25 are positioned against the ceiling of the conditioned space. In another embodiment, thedistribution network10 is positioned downward from the ceiling such that a lighting system may be mounted between theduct top surface25 and the room ceiling. Achamber assembly35 may extend upward from the junction boxtop surface38 to abut the ceiling for further securing thejunction box30 and also providing an aesthetically pleasing appearance.
One or more of thejunction boxes30 within thedistribution network10 includes anopening40 through which air is supplied from an air handler, such as a heating or air conditioning system.Air opening40 is positioned on one of the mountingsurfaces37 such that it is not visible to a viewer. Anair control mechanism29 may be positioned over theair opening40 to control or modify the flow of incoming air.
FIG. 4 illustrates theair distribution network10 positioned on the wall of a conditioned space. Conditioned air from the air handler enters the network throughair opening40 where it is directed throughducts20 andjunction boxes30. Achieving good thermal comfort within the conditioned space may not require aduct20 with diffusers on every wall of the conditioned space. However, theduct20 serves an aesthetic function that may motivate including aduct20 on every wall of the conditioned space. For reasons of economy, ducts may be fabricated without diffusers and may be installed in such a manner as not to conduct air. On the other hand, such ducts may be used to conduct air to another conditioned space. Therefore,junction boxes31 andducts21 are not equipped for conducting air through thedistribution network10. Theseaesthetic pieces21,31 have the same exterior surface as the functionalair distribution pieces20,30 such that a consistent aesthetic is maintained throughout the conditioned space.
Ducts20 andjunction boxes30 may also be used for removing air from the conditioned space. The aesthetic appearance of these elements is the same as the air distribution elements. Air from the conditioned space enters through inlets and is directed along theducts20 andjunction boxes30 to anexit port60. Air flow controllers may be positioned within thejunction boxes30 to further assist in the air movement.
FIG. 5 illustrates aduct20 constructed according to one embodiment of the present invention. Theduct20 is constructed ofseparate side sections52 and joiningedge elements62,64.Side sections52 may have a variety of shapes and orientations depending upon the desired cross-sectional dimensions of theduct20. As illustrated inFIG. 5, fourseparate side sections52 are joined together to form theduct20, although other numbers of different sections may be used to form the duct. Additionally,side sections52 may have a substantially straight orientation, or may have a curved orientation (not illustrated).
Joiningedge elements62,64 are positioned within the corners of theduct20 to connect theside sections52.Side sections52 are positioned against an inner edge of joiningedge elements62,64 and held in position by grippingbars72 andfasteners74. In the embodiment illustrated inFIG. 5,fasteners74 attach from the interior of the duct such that they are not visible to a viewer within the conditioned space. Serrated grooves within the joiningedge elements62,64 are sized to receive thefasteners74. Joiningedge elements62,64 may further form a section of theornamental surface22 and may include additional ornamentation to further improve the aesthetic appearance.
Elements64 may additionally be shaped to form therecess26 for hiding theoutlet28.Flow control mechanisms29 may further be positioned within theoutlets28.Projections27 may be mounted on the exterior surface of themounts62,64 to further enhance the aesthetic appearance and to obscure therecess26.
FIG. 6 illustrates one embodiment of the invention having anopening70 through which conditioned air moves from theinterior duct space80 to the conditionedspace100. Opening extends through the duct wall and includes afirst end72 at theinterior space80 and asecond end74 at the conditionedspace100. The profile of theduct20 is designed to obscure theopening70 such that it is not readily visible from the conditionedspace100. The term “profile” used herein means the exterior line formed by the exterior face of the duct. The profile of theduct20 in one embodiment is clearly visible in the cross-sectional view illustrated inFIG. 6. To a person in the conditionedspace100, the profile gives the impression that theduct20 is a decorative piece and serves no functional purpose.
Opening70 may be positioned at a variety of locations about theduct20. In one embodiment as illustrated inFIG. 6, opening70 is positioned adjacent to atop surface25 of theduct20 with thesecond end74 positioned at an junction between a front surface and atop surface25 of theduct20. In one embodiment as illustrated inFIG. 7, opening70 is positioned withsecond end74 positioned on thetop surface25.FIGS. 8 and 9 illustrate theopening70 positioned withsecond end74 positioned on the front surface. In one embodiment with the opening extending into the front surface, the profile of the ornamental surface design camouflages theopening70 such that it is visibly obscured.
In one embodiment, opening70 has an upwardly-slanted orientation to deliver conditioned air along theceiling surface102 of the conditioned space. In one embodiment, opening70 is slanted to deliver conditioned air along awall surface104. In another embodiment, opening70 is substantially flat.
In one embodiment, aprojection27 extends outward from the duct wall. In one embodiment,projection27 forms a part of theornamental surface22 that obscures theopening70. Aflow control mechanism29 is positioned within theprojection27 to control the flow of conditioned air through theopening70. In one embodiment,flow control mechanism29 is a rotatable member selectively positionable between a first position in which theopening70 is clear, a second position in which theopening70 is closed to prevent air flow, or a position therebetween. In one embodiment, acontrol lever50 extends outward from thecontrol mechanism29 for rotating thecontrol mechanism29. In one embodiment,flow control mechanism29 is positioned within the exterior duct wall. Theflow control mechanism29 is not visible from a person in the conditionedspace100, but acts to control the flow of air through theopening70. In one embodiment,flow control mechanism29 is positioned within the wall that includes theornamental surface22.
Lighting units90 may be positioned on theduct20. In one embodiment, lighting fixtures includes alight element94 and a clearprotective element92 which extends over thelight element94. In one embodiment as illustrated inFIGS. 6 and 7,lighting unit90 is positioned on thetop surface25 and theprotective element92 extends over the light to form a section of thetop surface25. In one embodiment illustrated inFIG. 9,lighting unit90 is positioned along the front surface. The profile of the duct obscures thelighting unit90 such that it is not visible from the conditioned space. In one embodiment, ornamental surface includes a recess for positioning thelighting unit90. The profile formed by the recess and the ornamental surface visibly obscures thelighting unit90 from a person in the conditionedspace100. In one embodiment as illustrated inFIG. 7, more than onelighting unit90 is positioned on theduct20.
Ducts20 may be positioned at a variety of locations within the conditionedspace100. In one embodiment as illustrated inFIG. 6,duct20 is positioned within the conditionedspace100 along a wall surface104 a short distance from aceiling102. In this embodiment, opening70 is angled to emit conditioned air along theceiling surface102.Lighting unit90 is positioned on thetop surface25 for lighting theceiling102. In one embodiment,duct20 is used as a shelf with thetop surface25 supporting items. In one embodiment as illustrated inFIGS. 8 and 9,duct20 is positioned along thewall surface104 with thetop surface25 positioned against theceiling102. In one embodiment,duct20 includes atab79 having an aperture through which a fastener is positioned to fasten theduct20 to thewall surface104.
In one embodiment,duct20 is formed from an extrusion process. In one embodiment as illustrated inFIG. 6, duct is constructed of afront section110,top section112, bottom section114, andback section116. One or more of the sections is constructed from an extrusion process. In one embodiment, the extruded sections have a length equal to the length of the conditionedspace100, such as a room as illustrated inFIG. 10. In one embodiment,front section110 includes theornamental surface22 and has a length equal to the length of the conditioned spaced100. The continuous piece ofduct20 adds to the aesthetic appearance because there are no connection joints which would result if smaller pieces were used. In one embodiment, front section is a continous length and is extruded without theopening70. The openings are machined through the duct wall in a separate step.Openings70 can be arranged at a variety of locations along the length of theduct20. In one embodiment, theduct20 is constructed of two extruded sections formed together as illustrated inFIG. 7. Afront section110 and aback section116 are extruded and then connected. In another embodiment,duct20 is constructed of a single extruded part. In another embodiment,duct20 is constructed of eight separate extruded sections which are connected together. In one embodiment, the extrusions are keyed or locked together. In one embodiment as illustrated inFIG. 7, thefirst section110 andsecond section116 mate together to form anintegral duct20. In one embodiment,sections110,116 slide together. In another embodiment,sections110,116 snap together. Various other keying or locking configurations may be used for attaching together the different sections. In one embodiment, the present invention provides for the different extruded pieces to connect to each other with minimal or no requirement for glue, adhesives, welding, or additional fasteners.
FIG. 10 illustrates one embodiment of theduct20 mounted within a conditionedspace100, such as a room.Duct20 extends along the length of one wall.Inlet40 brings conditioned air into theduct20 which is then transported and released to the conditionedspace100.Ducts21 have the same aesthetic appearance asduct20, but do not function to distribute conditioned air to or from the conditionedspace100. In the embodiment illustrated inFIG. 10,ducts21 extend along two walls. In another embodiment,ducts21 extend along each wall that is not occupied by afunctional duct20.
FIG. 11 illustrates ahanger150 for attaching theduct20 to thewall surface104.Hanger150 includes a downwardly-facingarm151 spaced a distance from a back edge of the duct to form agap152. Thegap152 is sized to receive ahanger106 mounted on and extending from thewall surface104. In this embodiment, a top edge of thehanger150 is substantially flush with thetop surface25 of theduct20. Thehanger150 may be positioned at a variety of locations along a back edge of theduct20 such that it is not visible from the perspective of a person standing within the conditioned space. A back edge of thearm151 is substantially flat to contact and rest against thewall surface104. Asupport surface154 is also positioned along a back edge of theduct20 to further support the duct on thewall surface104. Thesupport surface154 controls the orientation of the duct relative to thewall surface104 andceiling surface102. In the embodiment illustrated inFIG. 11, the outer edges of thesupport surface154 andarm151 are substantially aligned. An indent may further be positioned along the back surface. The indent is spaced inward from the plan formed by the surfaces of thearm151 andsupport154. In the embodiment ofFIG. 11, thearm151 extends into the indent to ease attachment to the wall.
As illustrated inFIG. 12, amember155 may be positioned at a lower edge of theduct20 to cover the point where the back edge of theduct20 contacts thewall surface104.Member155 may be aesthetically pleasing to match theornamental surface22, and further enhance the visual concept that the duct is cornice work placed on an upper section of thewall surface104. In this embodiment,member155 is an extension of a larger element that attaches to thewall surface104 and includes thehanger106.Member155 may also function as a holder for the protective element that extends over thelighting element94.
Apanel160 may be placed on thetop surface25 of theduct20. Thepanel160 includes aback edge161 that faces thewall surface104 and afront edge162. In one embodiment, the length of thepanel160 is about equal to the length of theduct20 such that theback edge161 contacts thewall surface104 and thefront edge162 is aligned with theopening70. Thefront edge162 may have an aesthetic appearance to enhance the overall visual appearance of theduct20. In one embodiment,front edge162 has an angled orientation. Thefront edge162 may further aid in directing the conditioned air as it leaves theopening70, such as further directing it along theceiling surface102.Panel160 may be constructed of an insulative material, such as foamed styrene. In one embodiment,panel160 is constructed of a compressible material.Panel160 is positioned between the top edge of theduct20 and the ceiling and has a width to prevent the duct from moving upward. Upon removal of thepanel160, theduct20 can be lifted upward and removed from the wall.
FIG. 13 illustrates anair deflector165 placed over thefront edge162 of thepanel160. Theair deflector165 extends to a section of the duct surface adjacent to theopening70. Thedeflector165 directs the air away from theduct20 and prevents the air from becoming trapped in thegap169 formed between the duct andpanel160.
FIG. 14 illustrates a joininginsert170 connecting twoseparate ducts20. The joininginsert170 has a smaller width to fit within the ends of theducts20. The inner width of theducts20 is slightly larger than the outer width of the joininginsert170 such that the insert can extend into the ducts. The smaller outer width of the joininginsert170 forms an offset171 with thelarger duct20. The width of theinsert170 may cause theinsert170 to be in close proximity to the inner edges of theducts20, or may contact the inner edges of theducts20. Theinsert170 may be sealed within theducts20 to prevent conditioned air from leaking. The seal may be by the contact between theinsert170 and theducts20, or may include a sealing agent such as caulk or glue positioned within the connection.
In one embodiment as illustrated inFIG. 14, the offset171 is facing thewall surface104 and provides a space for positioning anactuator wheel172 for controlling the positioning of theflow control mechanism29. Theactuator wheel172 is recessed within the offset171 so as not to visually diminish the aesthetic appearance of theduct20.
FIG. 15 illustrates another embodiment using acorner unit175 and a pair of joininginserts170 to connect theducts20 extending along two separate wall surfaces104. Thecorner unit175 includes first and second openings spaced about 90° apart and sized to each receive a joininginsert170. An offset171 is formed by the joininginsert170 between thecorner unit175 and theducts20. Anactuator wheel172 is positioned in each offset171 to control theair controller29 for each length ofduct20.
In one embodiment, theducts20 are mounted in an elevated location within a room. Theducts20 visually resemble cornice molding to provide an aesthetically pleasing appearance. The functional aspects of theduct20, such as theopening70 andflow control mechanism29, are hidden from view by theornamental surface22. Further, the joininginserts170 andcorner units175 provide for extending the duct network throughout an entire structure.
The present invention may be carried out in other specific ways than those herein set forth without departing from the scope and essential characteristics of the invention. In one embodiment, opening70 extends along the length of theduct20. In one embodiment, opening70 has a discrete length less than the length of theduct20. A series ofopenings70 are spaced along the length of theduct20. In one embodiment, the duct walls include an insulative liner. In one embodiment, insulative liner is positioned on the interior surface of theduct20. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.