Return air grille assembly

Abstract

An air grille assembly for installation within an aperture, the air grille assembly comprising: a frame comprising a frame outer portion and an insert portion, the frame having a top opening and a bottom opening; a grille having a front face and a rear face and comprising a panel, the panel having a plurality of passages extending therethrough; and at least one resiliently biased mounting clip that engages a rear surface adjacent the aperture to secure the air grille assembly within the aperture.

Description

Technical Field

[0001] This disclosure relates to heating and cooling systems, and more specifically, to air conditioners. Background Technology

[0002] In forced air heating and cooling systems, a fan associated with a furnace forces air through a duct system to distribute heated or conditioned air throughout the building. Air exits from outlets in the duct system, which typically include regulators operable to adjust the airflow into a room or space. For regulators located in the floor, grilles are often placed above the outlets or vents to provide an aesthetically pleasing appearance. Return air grilles or ventilation grilles draw air from a room or space and circulate it through the system to further regulate the air by cooling or heating, and can be installed in the walls, ceiling, or floor of the space. Return air grilles or ventilation grilles may include filters to reduce dust, debris, and contaminants, thereby improving indoor air quality.

[0003] In existing technology systems, return air grilles or ventilation grilles are laboriously fixed to walls, floors, or ceilings using fasteners (such as nails, screws, and bolts), which can result in an unsightly appearance. Summary of the Invention

[0004] In one aspect, an air grille assembly for installation within an orifice, the air grille assembly comprising:

[0005] A frame, comprising an outer frame portion and an insert portion, the frame having a top opening and a bottom opening;

[0006] A grille having a front and a rear and including a plate having a plurality of channels extending through the plate; and

[0007] At least one resilient bias mounting clip engages a rear surface adjacent to the orifice to secure the air grille assembly within the orifice.

[0008] In another aspect, an air grille assembly for installation within an orifice includes:

[0009] A grille, comprising a plate having a front and a rear, and a plurality of channels extending through the plate; and

[0010] At least one flexible bias mounting clip.

[0011] In another aspect, a method for installing an air grille assembly in an opening formed in at least one of a wall, ceiling, or floor surface, the method comprising the steps of:

[0012] Provided is the air grille assembly, the air grille assembly comprising: a grille including a plate having a plurality of channels extending through the plate, wherein the plate includes a front and a rear; a frame including at least one of a flange and a wall strip, the at least one of the flange and the wall strip being adapted to abut against a front surface adjacent to the orifice; and at least one resilient bias mounting clip including at least one resilient bias arm;

[0013] The grille is introduced into the opening, and at least one of the flange and the wall strip abuts against the front surface adjacent to the opening; and

[0014] The at least one resilient bias arm is positioned to engage a rear surface adjacent to the orifice, and a force is applied to the rear surface to secure the air grille assembly within the orifice.

[0015] Advantageously, the air grille assembly includes a resilient bias clip for mounting to the wall using fasteners (such as screws or nails) instead of existing methods. Attached Figure Description

[0016] Figure 1 A top view of the grid frame is shown;

[0017] Figure 2 It shows along Figure 1 The cross-sectional view of the grid frame taken by line AA in the figure;

[0018] Figure 3 It shows along Figure 1 The cross-sectional view of the grid frame cut by line BB in the middle;

[0019] Figure 4 A bottom view of the grid frame is shown;

[0020] Figure 5 A top-view perspective view of the grille frame is shown;

[0021] Figure 6 A bottom-view perspective view of the grille frame is shown;

[0022] Figure 7 A top view of a grille in one example is shown;

[0023] Figure 8 It shows along Figure 7 The cross-sectional view of the grid cut by line AA in the diagram;

[0024] Figure 9 A bottom-view perspective view of the grille is shown;

[0025] Figure 10 A bottom view of the grille with mounting clips is shown;

[0026] Figure 11 An exploded view of the mounting clips on the mounting structure of a grille in one example is shown;

[0027] Figure 12 A top view of the return air grille assembly is shown;

[0028] Figure 13 It shows along Figure 12 A cross-sectional view of the return air grille assembly taken from line AA in the diagram;

[0029] Figure 14 A bottom view of the return air grille assembly is shown;

[0030] Figure 15 An exploded view of the mounting clip on the mounting structure in another example is shown;

[0031] Figure 16 A top-view perspective view of the return air grille assembly is shown;

[0032] Figure 17 A bottom-view perspective view of the return air grille assembly is shown;

[0033] Figure 18 A top view of the grille in another example is shown;

[0034] Figure 19 It shows along Figure 17 The cross-sectional view of the grid cut by line AA in the diagram;

[0035] Figure 20 It shows along Figure 17 A cross-sectional view of the grid cut by line BB in the diagram;

[0036] Figure 21 A top perspective view of the grille with mounting clips is shown;

[0037] Figure 22 A bottom perspective view of the grille with mounting clips is shown;

[0038] Figure 23 It shows an opening formed in the wall and facing the space or room;

[0039] Figure 24 A return air grille assembly installed in a wall and facing a space or room is shown in one example.

[0040] Figure 25 A return air grille assembly installed in a wall and facing the plenum chamber is shown in one example.

[0041] Figure 26 A return air grille assembly, mounted in a wall and facing a space or room, is shown in one example; and

[0042] Figure 27 A return air grille assembly, mounted in a wall and facing the plenum chamber, is shown in one example. Detailed Implementation

[0043] The detailed description of exemplary embodiments herein refers to the accompanying block diagrams and schematic diagrams, which illustrate exemplary embodiments by way of illustration. While these exemplary embodiments have been described in sufficient detail to enable those skilled in the art to practice the invention, it should be understood that other embodiments may be implemented and logical and mechanical changes may be made. Therefore, the detailed description herein is presented for illustrative purposes only and not for limiting purposes. For example, the steps listed in any method or process description may be performed in any order and are not limited to the order presented.

[0044] Furthermore, it should be understood that the specific embodiments shown and described herein are illustrative of the invention and its best mode, and are not intended to further limit the scope of the invention in any way. In fact, for the sake of brevity, certain sub-components of other functionalities and individually operating parts of the system may not be described in detail herein.

[0045] See Figures 1 to 6 The diagram shows an air grille assembly (e.g., for installation in openings formed in the floor, ceiling, or wall) Figure 12 Example return air grille assembly 70 or Figure 18 The example is a return air grille assembly 80) with a grille frame 10. Air grille assemblies can be operated to return air to HVAC units via return air ducts of a heating, ventilation, and air conditioning (HVAC) system in a structure (such as a residence or building), although air grille assemblies can also be used for other applications. Thus, the orifice and the return air grille assembly are in fluid communication with the HVAC system. Typically, the air grille assembly can be positioned above the open end of a duct (such as a return air duct) or above a plenum chamber upstream of a duct associated with any of the systems described above. In one example, the surface can include materials such as wood, laminate, composite materials, plastics, ceramic tile, or drywall. In one embodiment, the air grille assembly includes grilles 11 housed within the air grille frame 10, as described later.

[0046] The grille frame 10 includes: an insertion portion 13 having a pair of longitudinally extending sidewalls 12a, 12b and a pair of laterally extending sidewalls 14a, 14b; and an outer portion 15. The sidewalls 12a, 12b, 14a, 14b are connected together to define a grille frame opening 16 extending between a spatial surface 17a of the grille frame 10 facing a space from which air is drawn (e.g., a room) and a plenum surface 17b of the grille frame 10 facing a return air duct or plenum chamber. The outer portion 15 includes: longitudinal wall strips 18a, 18b disposed at the spatial surface 17a adjacent to the longitudinally extending sidewalls 12a, 12b, respectively; and lateral wall strips 19a, 19b disposed at the spatial surface 17a adjacent to the laterally extending sidewalls 14a, 14b, respectively. Longitudinal wall strips 18a and 18b extend outward from longitudinally extending sidewalls 12a and 12b, respectively, and lateral wall strips 19a and 19b extend outward from laterally extending sidewalls 14a and 14b, respectively. Wall strips 18a, 18b, 19a, and 19b, including multiple holes 20, are adapted to abut against the front surface of material adjacent to the holes and are fixed thereto by mortar or joint cement. Longitudinal extending inner flanges 21a and 21b, respectively adjacent to longitudinally extending sidewalls 12a and 12b, extend inward into the grid frame opening 16; lateral extending inner flanges 22a and 22b, respectively adjacent to laterally extending sidewalls 14a and 14b, extend inward into the grid frame opening 16. Longitudinal extending inner flanges 21a and 21b each include a notch 23a, and lateral extending inner flanges 22a and 22b each include a notch 23b.

[0047] As in Figures 7 to 11 As can be seen, the grille 11 includes a panel 24 having a room-side or space-side surface 25a and a duct / plenum-side surface 25b, and a plurality of channels 26 extending between the room-side or space-side surface 25a and the duct / plenum-side surface 25b. On the duct / plenum-side surface 25b of the panel 24, a pair of longitudinally extending sidewalls 27a, 27b and a pair of laterally extending sidewalls 28a, 28b extend from the edge adjacent to the panel 24. Thus, for example, air from the room can flow through the channels 26 into the return air duct or plenum of the HVAC system.

[0048] In addition, the grille 11 includes one or more shields 29. The channels 26 and the shields 29 are spaced apart from each other at selected distances depending on various conditions. Some spacing considerations include airflow, aesthetic concealment of the filter (not shown) behind the grille 11, child safety, and other considerations known to, but not limited to, those of ordinary skill in the art. Typically, the shields 29 are oriented at a non-perpendicular angle relative to the side 25a of the space or room or the side 25b of the duct / plenum. In one example, the shields 29 are oriented at a 45-degree angle relative to the side 25a of the space or room or the side 25b of the duct / plenum. In some embodiments, the shields 29 may be divided into multiple groups of shields, wherein each group of shields 29 is configured in a spaced-apart configuration.

[0049] The paired longitudinally extending sidewalls 27a, 27b and the paired laterally extending sidewalls 28a, 28b include wall recesses 30. A mounting structure 32 adjacent to the wall recess 30 receives and secures a mounting clip 40, which is adapted to secure the air grille assembly within the opening, as described later. Each mounting structure 32 includes a clip mount 42 having opposing posts 45a, 45b and two protrusions 46a, 46b extending from the opposing posts 45a, 45b, as shown below. Figures 9 to 11 As shown. Opposite columns 45a and 45b are separated from each other by gap 47.

[0050] See Figure 11 The mounting clip 40 includes a spring body 52 and a support element 53. The spring body 52 has a first end portion 54a and a corresponding second end portion 54b, and is assembled to the clip mounting body 42 via a gap 47, such that the first end portion 54a and the second end portion 54b of the spring body 52 rest on two protrusions 46a, 46b, respectively. The support element 53 includes a first arm 60a, a middle portion 60b, and a second arm 60c connected together, and includes a tab 62 that can be gripped by a user during installation, as described below.

[0051] In one example, the spring body 52 is under tension and maintains the support element 53 substantially parallel to the plane of the pipe / static chamber side 25b.

[0052] In one example, such as Figures 12 to 17 As shown, the air grille assembly 70 includes two mounting clips 40 on both sides of the grille frame 36. See also Figures 23 to 25 The return air grille assembly 70 can be installed into the opening 90 in the floor, wall, or ceiling 92 by the following steps: starting from a first position where the support element 53 is substantially on the same plane as the plane of the duct / static pressure chamber side 25b, as... Figure 14 and Figure 15As shown, a force is applied to the tabs 62 of each mounting clip 40, forcing the support element 53 away from the plane of the pipe / static pressure chamber side 25b, causing the first arm 60a and the second arm 60c to rotate about the two protrusions 46a, 46b and move into a second position toward the clip mounting body 42 of the mounting structure 32. In this way, the applied force resists the force of the spring body 52.

[0053] In the second position, the spring body 52 is compressed, and the support element 53 is positioned to engage the edge of the orifice 90, allowing the support element 53 to enter the orifice 90. In one example, the support element 53 is substantially orthogonal to the pipe / static chamber side 25b.

[0054] When in the second position, the support element 53 of the mounting clip 40 is introduced into the aperture 90. In one example, the support element 53 is introduced into the aperture 90 such that a portion of the first arm 60a and a portion of the second arm 60c abuts the edge 94 of the aperture 90. As described above, these steps are performed on all mounting clips 40. In one example, these steps may be performed on the mounting clips 40 simultaneously or sequentially.

[0055] With a portion of the first arm 60a and a portion of the second arm 60c of all mounting clips 40 abutting the edge 94 of the orifice 90, a force is applied to the air grille assembly 70 to push it toward the orifice. This force causes the first arm 60a and the second arm 60c of the support element 53 to travel further into the orifice 90, while still under the tension of the spring body 52. ​​The force applied to the air grille assembly 70 eventually causes the first arm 60a and the third arm 60c to move away from the edge 94 of the orifice 90, and the force of the spring body 52 causes the first arm 60a and the second arm 60c to rotate about the two protrusions 46a, 46b, away from the clip mounting body 42 of the mounting structure 32, into the mounting position, in which the support element 53 is substantially coplanar with the plane of the pipe / static pressure chamber side 25b, similar to the first position. In the installation position, the first arm 60a, the second arm 60c, and the tab 62 are substantially parallel to the opposite side 25b of the floor, ceiling, or wall, and under the tension of the spring body 52, press against the pipe / static pressure chamber side surface 25b of the edge 94 of the orifice 90 adjacent to the floor, ceiling, or wall. Also in the installation position, the longitudinal wall strips 18a, 18b, the lateral wall strips 19a, 19b, and the space or room side 25a of the grille 11 are flush with the space or room-facing surface of the floor, ceiling, or wall. In one example, the depth d of the paired longitudinally extending sidewalls 27a, 27b and the paired laterally extending sidewalls 28a, 28b is determined to be substantially similar to the thickness of the floor, ceiling, or wall. In the installation position, the space or room side 25a of the air grille assembly 70 is held substantially flush with the surface of the floor, ceiling, or wall by the cooperation of the spring body 52 and the support element 53. Accordingly, the mounting clip 40 engages the opposite side of the wall or ceiling to secure the air grille assembly 70 within openings in common floors, walls, and ceilings of a certain thickness.

[0056] The mounting clip 40 is preferably made of a flexible material (such as metal), which allows the clip 40 to be formed by simple bending and stamping operations, resulting in relatively low production costs. The spring clip configuration allows for easy, simple, and quick installation and secure fastening of the air grille assembly 70 without the use of fasteners (such as screws or special tools).

[0057] At the installation location, filler or joint cement can be applied from the wall surface to the longitudinal wall strips 18a, 18b and the lateral wall strips 19a, 19b. Once dry, the longitudinal wall strips 18a, 18b and the lateral wall strips 19a, 19b can be sanded to provide a smooth, continuous surface from the wall to the longitudinal wall strips 18a, 18b and the lateral wall strips 19a, 19b.

[0058] In another example, such as Figures 18 to 22As shown, the air grille assembly 80 includes a grille 81 comprising a plate 24 having a space or room side 25a and a duct / pressure chamber side 25b, and a plurality of channels 26 extending between the space or room side 25a and the duct / pressure chamber side 25b. On the duct / pressure chamber side 25b of the plate 24, a pair of longitudinally extending sidewalls 27a, 27b and a pair of laterally extending sidewalls 28a, 28b extend from an edge adjacent to the plate 24. The pair of longitudinally extending sidewalls 27a, 27b and the pair of laterally extending sidewalls 28a, 28b are positioned away from the edge of the plate 24 such that a peripheral flange 82 is defined between the edge of the plate 24 and the sidewalls 27a, 27b, 28a, 28b. Similar to the grille 11, the grille 81 typically includes channels 26, a baffle 29, and a mounting structure 32 that receives and retains a mounting clip 40 adapted to secure the air grille assembly 80 within an orifice 90.

[0059] Air grille assembly 80 can be mounted in orifice 90 similarly to air grille assembly 70. In the mounted position, the first arm 60a, second arm 60c, and tab 62 are substantially parallel to the opposite or inner side of the floor, ceiling, or wall, and press against the inner surface of the floor, ceiling, or wall, i.e., a portion of the floor, ceiling, or wall adjacent to orifice 90, under the tension of spring body 52. ​​Peripheral flange 82 is flush with the surface of the floor, ceiling, or wall facing the space or room. In one example, the depth d of the pair of longitudinally extending sidewalls 27a, 27b and the pair of laterally extending sidewalls 28a, 28b is determined to be substantially similar to the thickness of the floor, ceiling, or wall. In the mounted position, peripheral flange 82 of air grille assembly 80 is held substantially flush with surface 25a of the floor, ceiling, or wall by the cooperation of spring body 52 and support element 53. Mounting clip 40 engages the opposite side 25b of the wall, ceiling, or floor to secure air grille assembly 80 within orifice 90 of common floors, walls, and ceilings of a certain thickness. Figure 26 An example of an air grille assembly 80 mounted in wall 92 and facing the space or room is shown; and Figure 27 An air grille assembly 80 is shown, installed in wall 92 and facing the static pressure chamber.

[0060] In another example, such as Figure 11As shown, the air grille assembly includes a grille 11 comprising a plate 24 having a space or room side 25a and a duct / pressure chamber side 25b, and a plurality of channels 26 extending between the space or room side 25a and the duct / pressure chamber side 25b. On the duct / pressure chamber side 25b of the plate 24, a pair of longitudinally extending sidewalls 27a, 27b and a pair of laterally extending sidewalls 28a, 28b extend from an edge adjacent to the plate 24. Similar to grille 11, grille 81 typically includes channels 26, a baffle 29, and a mounting structure 32 that receives and secures mounting clips 40 adapted to secure the air grille assembly within an orifice 90. In this example, the pair of longitudinally extending sidewalls 27a, 27b and the pair of laterally extending sidewalls 28a, 28b abut the edge 94 of the orifice 90.

[0061] Although the grid frames 10, 11 or 81, components 70, 80 shown in the figure typically form a closed rectangular configuration, the grid frames 10, 11 or 81, components 70, 80 may take other shapes, including circles, hexagons, etc., as needed.

[0062] In one example, the air grille assembly includes a grille frame 10 having: longitudinal wall strips 18a and 18b disposed at a spatial surface 17a adjacent to longitudinally extending sidewalls 12a and 12b, respectively; and lateral wall strips 19a and 19b disposed at a spatial surface 17a adjacent to laterally extending sidewalls 14a and 14b, respectively. The longitudinal wall strips 18a and 18b extend outward from the longitudinally extending sidewalls 12a and 12b, respectively, and the lateral wall strips 19a and 19b extend outward from the laterally extending sidewalls 14a and 14b, respectively. Thus, as described above, when the air grille assembly 70 is installed, the wall strips 18a, 18b, 19a, and 19b abut against the front surface adjacent to the opening 90.

[0063] In one example, an air grille assembly (such as example air grille assemblies 70, 80) directs air into a space or room.

[0064] The foregoing detailed description of exemplary embodiments of the invention has reference to the accompanying drawings, which illustrate exemplary embodiments by way of illustration. While these exemplary embodiments have been described in sufficient detail to enable those skilled in the art to practice the invention, it should be understood that other embodiments may be implemented and logical and mechanical changes may be made. For example, the steps listed in any of the claims in the method or process claims may be performed in any order and are not limited to the presented order. Furthermore, the invention may be practiced using one or more servers as needed. Therefore, the foregoing detailed description is presented for illustrative purposes only and not for limiting purposes, and the scope of the invention is defined by the foregoing description and with respect to the appended claims.

Claims

1. An air grille assembly for installation within an orifice, the air grille assembly comprising: A frame, comprising an outer frame portion and an insert portion, the frame having a top opening and a bottom opening; A grille having a front and a rear and including a plate having a plurality of channels extending through the plate; as well as At least one resilient bias mounting clip engages a rear surface adjacent to the orifice to secure the air grille assembly within the orifice.

2. The air grille assembly as claimed in claim 1, wherein, The outer portion of the frame is adapted to abut against the front surface adjacent to the orifice, and the insertion portion is received within the orifice.

3. The air grille assembly as claimed in claim 1, wherein, The opening is formed in at least one of the ceiling, wall, and floor, and wherein the air grille assembly is a return air grille.

4. The air grille assembly as claimed in claim 2, wherein, The frame includes a pair of longitudinally extending sidewalls and a pair of laterally extending sidewalls.

5. The air grille assembly as claimed in claim 4, wherein, The frame includes one or more mounting structures for securing the at least one resiliently biased mounting clip.

6. The air grille assembly as claimed in claim 5, wherein, Each mounting structure includes a clip mount having a notch and a protrusion extending from the opposite inner side of the notch.

7. The air grille assembly as claimed in claim 6, wherein, The at least one elastic bias mounting clip includes a support element and a spring body, the support element including a first arm, a middle portion, and a second arm, and the spring body having a first end portion and a second end portion.

8. The air grille assembly as claimed in claim 7, wherein, The first end portion and the second end portion rest on the protrusion.

9. The air grille assembly as claimed in claim 8, wherein, The first arm and the second arm extend from the first end portion and the second end portion of the spring body, respectively, and away from the clip mount.

10. The air grille assembly of claim 9, wherein, The outer portion includes at least one of a flange and a wall strip adjacent to the top opening, wherein at least one of the flange and the wall strip is adapted to abut against a front surface adjacent to the opening.

11. The air grille assembly of claim 10, wherein, The spring body is under tension and maintains the support element substantially parallel to the plane behind the grille.

12. The air grille assembly of claim 11, wherein, The air grille assembly is installed into the orifice in the following manner: (a) Starting from a first position in a plane substantially parallel to the plane behind the grille, a force is applied to the support element of the at least one resiliently biased mounting clip to push the support element away from the plane behind the grille, causing the first arm and the second arm to rotate about the protrusion toward the clip mount of the mounting structure to a second position. (b) When in the second position, the support element is introduced into the orifice; (c) Apply a force to the air grille assembly to push the air grille assembly into the orifice, thereby causing the first arm and the second arm to travel further into the orifice while still under the tension of the spring body, until the force of the spring body causes the first arm and the second arm to rotate about the protrusion away from the clip mount to a mounting position, in which the support element is substantially in the same plane as the plane behind the grille, and the first arm, the second arm and the middle portion abut the opposite side of the floor, ceiling or wall.

13. An air grille assembly for installation within an orifice, the air grille assembly comprising: A grille, the grille comprising a plate having a front and a rear, and a plurality of channels extending through the plate; The grille includes an outer portion and an insertion portion, wherein the outer portion is a part of the grille on the front side, and the insertion portion is a part of the grille that can be inserted into the orifice; as well as At least one flexible bias mounting clip.

14. The air grille assembly of claim 13, wherein, The opening is formed in at least one of a wall, ceiling, or floor, wherein the air grille assembly is at least one of a return air grille and a vent.

15. The air grille assembly of claim 13, further comprising at least one sidewall on the rear.

16. The air grille assembly of claim 15, further comprising at least one mounting structure for securing the at least one resiliently biased mounting clip for securing the air grille assembly within the orifice.

17. The air grille assembly of claim 16, wherein, At least one mounting structure includes a clip mount having a notch and a protrusion extending from the opposite inner side of the notch.

18. The air grille assembly of claim 17, wherein, The at least one elastic bias mounting clip includes a support element and a spring body, the support element including a first arm, a middle portion and a second arm, and the spring body having a first end portion and a second end portion.

19. The air grille assembly of claim 18, wherein, The first end portion and the second end portion rest on the protrusion.

20. The air grille assembly of claim 19, wherein, The spring body is under tension and maintains the support element substantially parallel to the plane behind the grille.

21. The air grille assembly of claim 20, further comprising a flange located between the plurality of channels and the edge of the plate.

22. The air grille assembly of claim 18, wherein, The air grille assembly is installed into the orifice in the following manner: (a) Starting from a first position in a plane substantially parallel to the plane behind the grille, a force is applied to the support element of the at least one resiliently biased mounting clip to push the support element away from the plane behind the grille, causing the first arm and the second arm to rotate about the protrusion toward the clip mount of the mounting structure to a second position. (b) When in the second position, the support element is introduced into the orifice; (c) Apply a force to the air grille assembly to push the air grille assembly into the orifice, thereby causing the first arm and the second arm to travel further into the orifice while still under the tension of the spring body, until the force of the spring body causes the first arm and the second arm to rotate about the protrusion away from the clip mount to a mounting position, in which the support element is substantially in the same plane as the plane behind the grille, and the first arm, the second arm and the middle portion abut the opposite side of the floor, ceiling or wall.

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