Plenum for an air treatment system

Abstract

A plenum (1) for an air treatment system, said plenum comprising a body (50) defined by a back wall (2), a first and a second side walls (3 and 4), a front wall (5) and a first and second closing walls, said back wall having an inlet opening (8) for entry of said air into said body, and said front wall having one or more outlet openings (81) for said air, said first and second closing walls comprising a first and a second preformed frames (10 and 11) of quadrangular shape, each frame of said first and second frames having connection means (12) with said back wall, with said first and second side walls and with said front wall, and housing means (13) for a closing cap (14) for each said frame.

Description

[0001] PLENUM FOR AN AIR TREATMENT SYSTEM

[0002] DESCRIPTION

[0003] BACKGROUND OF THE INVENTION

[0004] The present invention relates to a plenum for an air treatment system.

[0005] As is known, plenums are used to connect the air supply and return from the air conditioning unit and can be equipped with two or more outlet openings to which flexible ducts are connected, supplying the vents or nozzles present in the rooms.

[0006] Consequently, each plenum is specifically manufactured from time to time at least based on the dimensions and type of air conditioning unit and the number of vents to be supplied.

[0007] Considering that plenums are made of pre-insulated panel (aluminum - polyurethane insulation - aluminum) or sheet metal, the aforementioned situation results in significant drawbacks mainly due to the following reasons.

[0008] It is not possible to keep numerous plenums in stock for immediate use due to their large size and, consequently, the high storage costs.

[0009] It is not possible to obtain plenums quickly because, if they are ordered from the factory according to specific technical needs, delivery times are long and delay the installation of the entire air conditioning system.

[0010] If the plenum is manufactured in the factory, whether by cutting panels or sheets with precision machinery or by manually cutting the latter, it requires several gluing or welding operations on the cut components resulting in the need for skilled labor.

[0011] If, on the other hand, the plenum is manufactured at the installation site, the production time is considerable and it is still necessary to have skilled labor, as there is always the possibility of manufacturing errors.

[0012] Normally, in fact, the production of a plenum for air conditioning systems consists of taking a sheet of foamed polyurethane coated with a metal sheet, made of aluminum, or galvanized sheet metal, or other materials, and making three parallel grooves on it with faces inclined at 45 degrees so as to divide the sheet into a back wall, a front wall and two side walls, or simply assembling six separate pieces also taking into account the two closing walls.

[0013] The edges of the back wall and those of the side walls are also cut at 45 degrees to accommodate closing walls, which also have edges cut at 45 degrees to fit together with the edges of the back wall, the front wall and the side walls.

[0014] The next step consists of applying adhesive in the grooves and bending the two side walls at 90 degrees relative to the back wall and the front wall and then attaching the closing walls, also by gluing.

[0015] The entire assembly is then sealed with silicone along all the junction edges to ensure a good rigidity of the box.

[0016] From the above it is clear that the construction of a plenum for an air conditioning system presents numerous drawbacks mainly due to the fact that there are several variables that lead to a dedicated and custom-made production of the plenum each time both depending on the different sizes of the machines to which it must be connected, and on the different diameters and number of connections to which it has to be coupled for the transport of air to the various rooms to be conditioned.

[0017] Furthermore, the use of adhesives and silicones for their construction, in addition to the environmental pollution and occupational health issues, results in long production times due to the drying time thereof required before transportation and installation of each support box.

[0018] It must then be considered that the plenum inlet opening must perfectly match the outlet opening of the air conditioning unit and any measurement error results in the rejection of the plenum.

[0019] The same applies to the addition into the same plenum of the inlet opening for fresh air from VMC systems which is more and more used in the latest generation buildings.

[0020] All these issues become even more significant when the plenum is made of sheet metal.

[0021] Last but not least, it should be noted that the aforementioned drawbacks significantly impact the cost of constructing an air conditioning system. In summary, consequently, there are high costs both for machinery and labor for the custom construction of plenums, which almost always differ from one another.

[0022] All this results, as seen, in high production costs and a lack of flexibility in preparing the necessary machinery for any change in dimensions, modifications or different types of plenums.

[0023] From patent IT201900004341 U1 a plenum is also known for an air treatment system that comprises a body defined by a back wall, a first and a second side walls, a front wall and a first and a second closing walls.

[0024] The back wall has an inlet opening for entry of the treated air into the plenum body and the front wall has one or more air outlet openings.

[0025] However, this patent neither describes nor suggests that the first and second closing walls comprise a first and a second preformed frames of quadrangular shape and a closure cap for the frames which, on the side facing said body, have connection means with the back wall, with the first and second side walls and with the front wall and, on the side opposite to the body, housing means for the cap for the simultaneous closure of each frame and the plenum body.

[0026] SUMMARY OF THE INVENTION

[0027] The aim of the present invention is to eliminate the aforementioned drawbacks of the prior art.

[0028] Within this aim, an important object of the invention is to design a plenum for an air treatment system that can be manufactured and squared automatically without the use of adhesives.

[0029] Another object is to create a plenum for an air treatment system that allows for its construction directly at the installation site without the use of adhesives and silicones, automatically achieving both the squaring of its walls and an optimal level of rigidity for the installation thereof and the immediate coupling to the air conditioning unit.

[0030] A further object is to create a plenum for an air treatment system that can be stored and transported with an extremely limited bulk as it has a flat configuration and not a box-like one.

[0031] Yet another object is to create a plenum for an air treatment system that allows for its construction in very short times, at least 70% less than a traditional plenum as it is completed dry without the use of adhesives and / or silicones.

[0032] A further object of the invention is to create a plenum for an air treatment system that can be manufactured in a very short time without the need for skilled labor and without complex cutting or shaping operations on the sheet metal both in the workshop and at the installation site.

[0033] Yet another object of the invention is to create a plenum for an air treatment system that allows for a fast and cost-effective construction thereof regardless of the number of outlet openings.

[0034] Last but not least, an object of the invention is to create a plenum for an air treatment system that is already designed to receive fresh air from the VMC system without requiring any modifications.

[0035] The above objects also apply particularly in the case of sheet metal plenums.

[0036] This aim as well as these and other objects are achieved by a plenum (1 ) for an air treatment system as claimed in claim 1 .

[0037] BRIEF DESCRIPTION OF THE DRAWINGS

[0038] These characteristics and advantages of the invention will become more apparent from the following indicative and non-limiting description of preferred but not exclusive embodiments of a plenum for an air treatment system illustrated in the following figures, in which:

[0039] Fig. 1 is a perspective view of a plenum for an air treatment system according to the invention;

[0040] Fig. 2 is an exploded perspective view of a plenum for an air treatment system according to the invention;

[0041] Fig. 3 is a front elevation view of the inner face of the preformed frame according to the invention; Fig. 4 is a perspective view of the inner face of the preformed frame according to the invention;

[0042] Fig. 5 is a perspective view of the foamed polyurethane sheet that forms the walls of a plenum for an air treatment system according to the invention.

[0043] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0044] With particular reference to the figures mentioned above, the plenum for an air treatment system is generally indicated with the reference number 1 .

[0045] The plenum 1 comprises a body 50 defined by a back wall 2, a first and a second side walls 3 and 4, a front wall 5, a first and a second closing walls, which, as will be seen, are defined by a cap 14.

[0046] The back wall has an inlet opening 8 for entry of air into the body 50 from the air conditioning unit.

[0047] The first and second closing walls comprise a first and a second preformed frames, respectively, indicated as a whole with 10 and 11.

[0048] Each frame has connection means 12 for connecting with the back wall, the first and second side walls and the front wall.

[0049] Advantageously, the connection means simultaneously allow for the automatic squaring of the entire plenum body and provide it with optimal rigidity so that it can be handled and installed without any deformation issues immediately after its assembly, which can also be carried out at the installation site by the installer himself, without the need for skilled labor.

[0050] The plenum also has housing means 13 for a cap 14 which is also normally made of the same material as the plenum body or another material suitable for the purpose.

[0051] Additionally, the first and second frames each have a quadrangular shape comprising two first opposite sides 45 and two second opposite sides 46.

[0052] The first sides 45 are longer than the second sides 46 giving each frame a rectangular shape so that, when needed, rotating the frames results in an increase or decrease in the height and depth of the plenum allowing it to adapt to the dimensions of the false ceiling in which it is installed. The rotation of the frames, simply varying the width of the back wall 2 that fits onto the rectangular frames and forms the inlet wall for the conditioned air generated by the air conditioning unit to which the plenum is coupled, allows for coupling to small- and medium-sized air conditioning units (shorter sides) or to medium- and large-sized air conditioning units (longer sides).

[0053] The connection means 12 comprise a continuous channel 17 that extends along the perimeter of each frame and, consequently, also has a rectangular shape.

[0054] The inlet opening 8 has a first and a second profiles 15 and 16 which can be associated with the first side wall and the back wall, respectively, and which, consequently, define the transverse width of the inlet opening.

[0055] The first profile 15 has a substantially "h" shape while the second profile 16 has an "F" shape, both with the base of the "h" and the "F" engaging the edges of the side and back walls while the upper stem of the "h" and the "F" create the connection to the air conditioning unit not shown and of a known type.

[0056] The plenum also has housing means 13 for a closing cap 14 for each frame.

[0057] Normally, the closing cap is made of the same material as the plenum body but it could also be made of other types of materials.

[0058] The housing means comprise a cap support bracket 18 which includes fastening means 19 for securing said cap.

[0059] The fastening means 19 allow each cap 14 to be attached to its respective frame, for example, through clips 30 that are inserted into the respective cap, via dedicated slots 31 .

[0060] The caps 14 can accommodate an outlet of a duct, not shown, carrying conditioned air if it is more convenient to connect it transversely to the conditioned air outlet and therefore on the side wall of the plenum, or a duct for connecting the plenum to a VMC system can be attached.

[0061] Each frame comprises oriented support means 70 for at least one dividing wall 20, suitable to divide the interior of said plenum into a first and a second chambers 21 , 22.

[0062] The dividing wall is composed of two inclined parts 40 and 41 that form an angle greater than 90 degrees.

[0063] The two inclined parts of the dividing wall appropriately allow for the compartmentalization of said plenum, creating the first chamber 21 for the passage of fresh air coming from the VMC system, for example, through the inlet opening 71 (shown in dashed lines in Fig. 2) created on the caps 14.

[0064] In particular, the first oriented support means 70 comprise a first guide 25 and a second guide 26 into which the dividing wall is engaged.

[0065] The first guide features two inclined walls 42 relative to the two first and two second sides of the frame whereas the second guide features two orthogonal walls 43 relative to the two first and two second sides 45 and 46 of the frame.

[0066] Advantageously, the continuous channel 17 internally has a plurality of teeth 44 each having one inclined wall and one orthogonal to the bottom of the continuous channel to facilitate the insertion of the edges of the plenum body walls into it.

[0067] In this way, once the preformed rectangular frames are attached to the plenum walls, they will no longer detach unless a significant separating force is applied to them.

[0068] The teeth 44 are arranged alternately on the outer and inner walls of the channel 17 to evenly distribute the retaining forces on the back, side and front walls.

[0069] The present invention also relates to a method for manufacturing a plenum for air conditioning systems which consists of making three parallel grooves 80 with double 45-degree beveled cuts, not passing through, on a sheet of foamed polyurethane coated with a metal foil in order to divide it into a back wall 2 and two side walls 3 and 4 and a front wall 5 on which the air conditioning and VMC outlet openings 81 are indicated in dashed lines.

[0070] Additionally, the caps 14 of equal size are made with 90-degree cuts along their perimeter.

[0071] Subsequently, the side walls 3 and 4 and the front wall 5 are bent at 90 degrees to each other, without the use of adhesives, forming a partially closed parallelepiped body as the back wall 2 is always narrower than the front wall 5, preventing a squared alignment and leaving the front wall detached from the opposite side wall.

[0072] Finally, onto opposite parts of the back, front, and side walls are connected the two preformed rectangular closing frames 10 and 11 which have connection means for connecting to the back, side, and front walls for their automatic squaring also providing an optimal structural rigidity.

[0073] On each of the side walls, profiles 15 and 16 are connected to form the inlet opening 8 for conditioned air from the box and onto which the air conditioning unit is connected.

[0074] The above-described operations, with the exception of the parallel grooves 80 which are made in the workshop, can easily be carried out directly at the installation site of the box without any special tools and in very short times.

[0075] This allows for simplified storage and transport since the sheet is flat and occupies a small space.

[0076] It should also be noted that the box of the invention can be easily manufactured in any size to be compatible with all ducted air conditioning units currently on the market as well as non-standard special machines since it will only be necessary to cut the foamed polyurethane sheet to size to adjust the dimensions thereof and accordingly use appropriately sized caps.

[0077] The plenum for an air conditioning system conceived in this way is subject to modifications and variations all of which fall within the inventive concept, furthermore the materials and dimensions can be any according to requirements.

Claims

CLAIMS1. Plenum (1 ) for an air treatment system, said plenum comprising a body (50) defined by a back wall (2), a first and a second side walls (3 and 4), a front wall (5) and a first and a second closing walls, the back wall having an inlet opening (8) for entry of the treated air into the plenum body and the front wall having one or more air outlet openings (81 ), characterized in that said first and second closing walls comprise a first and a second preformed frames (10 and 11 ) of quadrangular shape and a closing cap (14) for the frames, the frames having on their parts facing said body (50) connection means (12) with the back wall, with the first and second side walls and with the front wall, and, on their parts opposite the body (50), housing means (13) for the cap (14) for the simultaneous closure of each frame and of the plenum body.

2. Plenum (1 ) for an air treatment system according to claim 1 , characterized in that said inlet opening has a first and a second profiles (15 and 16) that can be associated with said first side wall and said back wall, respectively.

3. Plenum (1 ) for an air treatment system according to claim 2, characterized in that said first and second profiles define the transverse width of said inlet opening.

4. Plenum (1 ) for an air treatment system according to claim 1 , characterized in that said connection means comprise a continuous channel (17) extending around the perimeter on each said frame.

5. Plenum (1 ) for an air treatment system according to claim 1 , characterized in that said housing means comprise a support bracket (18) for said cap.

6. Plenum (1 ) for an air treatment system according to claim 5, characterized in that said bracket comprises fastening means (19) for said cap.

7. Plenum (1 ) for an air treatment system according to claim 1 , characterized in that each said frame comprises oriented support means (70) for at least one dividing wall (20), said dividing wall dividing the interior of said plenum into a first and a second chambers (21 , 22).

8. Plenum (1 ) for an air treatment system according to claim 7, characterized in that said dividing wall is formed by two parts (41 and 42) inclined to each other at an angle greater than 90 degrees.

9. Plenum (1 ) for an air treatment system according to claim 1 , characterized in that each said frame comprises two first mutually opposite sides (45) and two second mutually opposite sides (46), said first sides being longer than said second sides.

10. Plenum (1 ) for an air treatment system according to one or more of the preceding claims, characterized in that said first oriented support means comprise a first guide (25) and a second guide (26), said first guide having two inclined walls (42) relative to said two first and two second sides of said frame, and said second guide having two orthogonal walls (43) relative to said two first and two second sides of said frame.

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