Air diffuser and mounting plate thereof

Abstract

A mounting plate for an air diffuser assembly. The mounting plate includes a body and a plurality of mating features provided on the body to make a plurality of air diffuser configurations compatible with the mounting plate. Each mating feature is configured to support mounting of an air diffuser of a distinct air diffuser configuration.

Description

AIR DIFFUSER AND MOUNTING PLATE THEREOFBACKGROUND

[0001] The present disclosure relates generally to air diffusers for use in heating, ventilation, and air conditioning (HVAC) systems. More particularly, the present disclosure relates to air diffusers and mounting plate thereof.

[0002] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

[0003] Air diffusers may be utilized to distribute air from a duct into an interior space such as a room, office, and / or other space of a building. Additionally, air diffusers may be coupled to an outlet of the duct that is configured to transfer conditioned air from an air handler or ventilation air from a dedicated outdoor air system to the interior space. Typically, air diffusers are mounted to a ceiling, wall, and / or floor of the interior space using mounting plates, for example, a backpan. With air diffusers of different configurations available, equipment manufacturers have traditionally provided a multitude of mounting plates, each tailored to specific air diffuser configuration. However, such approach leads to complicated inventory management and increased production complexity. There is therefore, felt a need to provide a mounting plate capable of accommodating different air diffuser configurations and / or to align air diffuser configurations with a universal mounting plate.SUMMARY

[0004] One implementation of the present disclosure relates to a mounting plate. The mounting plate includes a body and a plurality of mating features provided on the body to make a pluralityof air diffuser configurations compatible with the mounting plate. Each mating feature is configured to support mounting of an air diffuser of a distinct air diffuser configuration.

[0005] In some embodiments, the body includes a center portion having an opening. The mounting plate is configured to be fluidly coupled to a ductwork via the opening.

[0006] In some embodiments, the plurality of mating features include one or more slots and one or more weld projections.

[0007] In some embodiments, the one or more slots and the one or more weld projections are provided on the center portion of the body.

[0008] In some embodiments, the one or more slots support mounting of an air diffuser having a first air diffuser configuration and the one or more weld projections support mounting of another air diffuser having a second air diffuser configuration. The first air diffuser configuration is different from the second air diffuser configuration.

[0009] In some embodiments, the body further includes a wall portion coupled to the center portion and extending away from the opening.

[0010] In some embodiments, the wall portion functions as one of the plurality of mating features to couple an air diffuser having a third air diffuser configuration with the mounting plate.

[0011] In some embodiments, the body further includes a plurality of edges such that the wall portion is provided between the plurality of edges and the center portion.

[0012] In some embodiments, the plurality of edges function as one of the plurality of mating features.

[0013] In some embodiments, one or more edges of the plurality of edges are configured to couple with an air diffuser having a fourth air diffuser configuration.

[0014] Another implementation of the present disclosure relates to an air diffuser assembly. The air diffuser assembly includes a mounting plate and a diffusion plate. The mounting plate includes a center portion with an opening, a plurality of edges, and a wall portion with a first end coupled to the center portion and a second end coupled to the plurality of edges. The mounting plate is configured to be fluidly coupled to ductwork via the opening. The diffusion plate comprises a plurality of hemmed edges configured to slidably engage with the plurality of edges of the mounting plate to couple the diffusion plate to the mounting plate.

[0015] In some embodiments, the air diffuser assembly further includes a deflector plate coupled to the mounting plate and disposed over the opening.

[0016] In some embodiments, the deflector plate is positioned between the mounting plate and the diffusion plate.

[0017] In some embodiments, the air diffuser assembly further includes a frame coupled to the plurality of hemmed edges to secure the slidable engagement of the plurality of hemmed edges with the plurality of edges of the mounting plate.

[0018] In some embodiments, the diffusion plate includes a perforated section that covers the opening.

[0019] Another implementation of the present disclosure relates to an air diffuser assembly. The air diffuser assembly includes a mounting plate and an air diffuser. The mounting plate comprises a center portion with an opening, a plurality of edges, and a wall portion with a first end coupled to the center portion and a second end coupled to the plurality of edges. The mounting plate is configured to be fluidly coupled to ductwork via the opening. The air diffuser includes a base portion and a plurality of walls extending from the base portion. The air diffuser is positioned over the mounting plate such that the plurality of walls surround the plurality of edges. The air diffuser has a plurality of support members that securely engage with the wall portion to couple the air diffuser to the mounting plate.

[0020] In some embodiments, the plurality of support members are a plurality of fasteners inserted into the plurality of walls.BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Various objects, aspects, features, and advantages of the disclosure will become more apparent and better understood by referring to the detailed description taken in conjunction with the accompanying drawings, in which like reference characters identify corresponding elements throughout. In the drawings, like reference numbers generally indicate identical, functionally similar, and / or structurally similar elements.

[0022] FIG. 1 is a diagram that illustrates a heating, ventilation, and / or air conditioning (HVAC) system for building environmental management that may employ one or more HVAC units, according some embodiments of the present disclosure.

[0023] FIG. 2 is a diagram that illustrates a mounting plate compatible with air diffusers of a plurality of configurations, according to some embodiments of the present disclosure.

[0024] FIG. 3 A is a diagram that illustrates an air diffuser assembly, according to a first embodiment of the present disclosure.

[0025] FIG. 3B is a diagram that illustrates a partial cross-sectional side view of the air diffuser assembly of FIG. 3 A along line A- A, in accordance with the first embodiment of the present disclosure.

[0026] FIG. 4A is a diagram that illustrates an air diffuser assembly, according to a second embodiment of the present disclosure.

[0027] FIG. 4B is a diagram that illustrates an isometric view of the air diffuser assembly of FIG. 4A, in accordance with the second embodiment of the present disclosure.

[0028] FIGS. 5A and 5B are diagrams that illustrate an air diffuser assembly, according to a third embodiment of the present disclosure.

[0029] FIGS. 5C and 5D are diagrams that illustrate scenarios for mounting the air diffuser assembly of FIGS. 5A and 5B, according to the third embodiment of the present disclosure.

[0030] FIGS. 6A and 6B are diagrams that illustrate an air diffuser assembly, according to a fourth embodiment of the present disclosure.DETAILED DESCRIPTION

[0031] One or more specific embodiments will be described below. In an effort to provide a concise description of these embodiments, not all features of an actual implementation are described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0032] When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.Overview

[0033] In heating, ventilation, and air conditioning (HVAC) systems, diffusers are commonly used to diffuse, distribute, or throw a conditioned air flow from a duct into a conditioned space. Typically, air diffusers are mounted to a ceiling, wall, and / or floor of the interior space using mounting plates, for example, a backpan. With air diffusers of different configurations available,equipment manufacturers have traditionally provided a multitude of mounting plates, each tailored to specific air diffuser configuration. However, such approach leads to complicated inventory management and increased production complexity.

[0034] The present disclosure aims to overcome the abovementioned shortcomings by providing a mounting plate (e.g., a backpan) that is compatible with a plurality of air diffuser configurations. The mounting plate includes a plurality of mating features, each mating feature configured to support mounting of an air diffuser of a distinct air diffuser configuration. The plurality of mating features may include slots, weld projections, protruding edges, tapered wall portions, etc.

[0035] Before turning to the Figures, it should be understood that the disclosure is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

[0036] Referring generally to the Figures, a diffuser with concealed fastening is shown and described.Building HVAC System

[0037] Turning now to the drawings, FIG. l is a diagram that illustrates a heating, ventilation, and / or air conditioning (HVAC) system for building environmental management that may employ one or more HVAC units, according some embodiments of the present disclosure. A building may include an HVAC system that may employ one or more HVAC units for building environmental management. As used herein, an HVAC system includes any number of components configured to enable regulation of parameters related to climate characteristics, such as temperature, humidity, air flow, pressure, air quality, and so forth. For example, an “HVAC system” as used herein is defined as conventionally understood and as further described herein. Components or parts of an “HVAC system” may include, but are not limited to, all, some of, or individual parts such as a heat exchanger, a heater, an air flow control device, such as a fan, asensor configured to detect a climate characteristic or operating parameter, a filter, a control device configured to regulate operation of an HVAC system component, a component configured to enable regulation of climate characteristics, or a combination thereof. An “HVAC system” is a system configured to provide such functions as heating, cooling, ventilation, dehumidification, pressurization, refrigeration, filtration, or any combination thereof. The embodiments described herein may be utilized in a variety of applications to control climate characteristics, such as residential, commercial, industrial, transportation, or other applications where climate control is desired.

[0038] In the illustrated embodiment, a building 10 is serviced by an HVAC system 11 that includes an HVAC unit 12. The building 10 may be a commercial structure or a residential structure. As shown, the HVAC unit 12 is disposed on the roof of the building 10; however, the HVAC unit 12 may be located in other equipment rooms or areas adjacent the building 10. The HVAC unit 12 may be a single, packaged unit containing other equipment, such as a blower, integrated air handler, and / or auxiliary heating unit. In other embodiments, the HVAC unit 12 may be part of a split HVAC system, which includes an outdoor HVAC unit and an indoor HVAC unit.

[0039] The HVAC unit 12 is an air cooled device that implements a refrigeration cycle to provide conditioned air to the building 10. Specifically, the HVAC unit 12 may include one or more heat exchangers across which an air flow is passed to condition the air flow before the air flow is supplied to the building. In the illustrated embodiment, the HVAC unit 12 is a rooftop unit (RTU) that conditions a supply air stream, such as environmental air and / or a return air flow from the building 10. After the HVAC unit 12 conditions the air, the air is supplied to the building 10 via ductwork 14 extending throughout the building 10 from the HVAC unit 12. For example, the ductwork 14 may extend to various individual floors or other sections of the building 10. In certain embodiments, the HVAC unit 12 may be a heat pump that provides both heating and cooling to the building 10 with one refrigeration circuit configured to operate in different modes. In other embodiments, the HVAC unit 12 may include one or more refrigeration circuits for cooling an air stream and a furnace for heating the air stream.

[0040] To facilitate controlling operation of the HVAC equipment (for example, the HVAC unit 12), the HVAC system 11 may include a control system. In some embodiments, the control system may be implemented using one or more control devices 16, such as a thermostat, a zone sensor, a zone control panel, a pressure transducer, and / or a temperature transducer. For example, a control device 16 may be a thermostat used to designate target air conditions, such as target temperature and / or target humidity level, within the building 10 and / or that measures air conditions present within the building 10. The control device 16 also may be used to control the flow of air through the ductwork 14 based at least in part on the target air conditions and measured air conditions. For example, the control device 16 may be used to regulate operation of one or more components of the HVAC unit 12 or other components, such as dampers and fans, within the building 10 that may control flow of air through and / or from the ductwork 14. For example, when the difference between the measured temperature and the target temperature is greater than a threshold, the control system may turn on or run the HVAC unit 12 to circulate refrigerant through one or more heat exchangers to facilitate producing temperature-controlled air. Additionally, the control system may turn on a fan and / or adjust position of an air damper to facilitate supplying the temperature-controlled air to internal spaces within the building 10 via the ductwork 14.

[0041] In some embodiments, other devices may be included in the system, such as pressure and / or temperature transducers or switches that sense the temperatures and pressures of the supply air, return air, and so forth. Moreover, the control device 16 may include computer systems that are integrated with or separate from other building control or monitoring systems, and even systems that are remote from the building 10.

[0042] To facilitate producing temperature-controlled air, in some embodiments, the HVAC unit 12 may be selectively operated in different modes, such as a first-stage cooling mode, a second-stage cooling mode, a fan only mode, a first-stage heating mode, and a second-stage heating mode. For example, when operating in a heating mode or heat pump mode, the HVAC unit 12 may inject heat to produce heated air, which may then be supplied to internal spaces within the building 10. Additionally, or alternatively, the HVAC system 11 may include afurnace that operates to produce the heated air. Furthermore, when operating in a cooling mode or air conditioning mode, the HVAC unit 12 may extract heat to produce cooled air, which may then be supplied to internal spaces within the building 10.

[0043] It should be appreciated that any of the features described herein may be incorporated with the HVAC unit 12, residential heating and cooling systems, or other HVAC systems. Additionally, while the features disclosed herein are described in the context of embodiments that directly heat and cool a supply air stream provided to a building or other load, embodiments of the present disclosure may be applicable to other HVAC systems as well. For example, the features described herein may be applied to mechanical cooling systems, free cooling systems, chiller systems, or other heat pump or refrigeration applications.

[0044] The ductwork 14 may include a primary duct 18, which may be fluidly coupled with an output of the HVAC unit 12 at a first end 20. Accordingly, the primary duct 18 may direct the conditioned air from the HVAC unit 12 towards one or more air diffusers 22. In some embodiments, a second end 24 of the primary duct 18 may be positioned at or near one or more lowermost interior spaces (e.g., first floor) along the primary duct 18 (e.g., when the primary duct 18 extends vertically along multiple floors of the building 10). In other embodiments, the second end 24 may be positioned at or near one or more interior spaces furthest from the first end 20 of the primary duct 18 (e.g., when the primary duct 18 extends along a single floor of the building 10). In still further embodiments, the second end 24 may be positioned at any suitable location within or external to the building 10. Additionally, the ductwork 14 may include one or more secondary ducts 26. The secondary ducts 26 may be configured to direct conditioned air from the primary duct 18 to the air diffusers 22. Therefore, a first end 28 of each of the secondary ducts 26 may be fluidly coupled to the primary duct 18 and a second end 30 of each of the secondary ducts 26 may be fluidly coupled to a respective air diffuser 22. Each air diffuser 22 may be configured to disperse conditioned air into a respective interior space, thereby providing heating, cooling, and / or ventilation to the interior space. Air diffusers 22 are available in multiple configurations, each tailored to meet specific application and performance requirement.Examples of different air diffuser configurations may include, but are not limited to, swirl diffusers, plaque diffusers, cone diffuser, perforated diffusers, or the like.

[0045] Typically, air diffuser 22 is mounted to a ceiling, wall, and / or floor of the interior space using a mounting plate, for example, a backpan. With air diffusers 22 of different configurations available, equipment manufacturers have traditionally provided a multitude of mounting plates, each tailored to a specific air diffuser configuration. For example, mounting plate used to mount a perforated diffuser may be different from a mounting plate used to mount a swirl diffuser. However, such approach leads to complicated inventory management and increased production complexity. Present disclosure overcomes these shortcoming by providing a universal mounting plate capable of accommodating different air diffuser configurations and / or by aligning air diffuser configurations for use with the universal mounting plate.Universal mounting plate

[0046] FIG. 2 is a diagram that illustrates a mounting plate 100 compatible with air diffusers of a plurality of configurations, according to some embodiments of the present disclosure.

[0047] The mounting plate 100 may be coupled to the second end 30 of a respective secondary duct 26 described in the foregoing description of FIG. 1. The mounting plate 100 may have a body 101. The body 101 of the mounting plate 100 may include an opening 102 that may be placed over an outlet of the respective secondary duct 26 at the second end 30. For example, the opening 102 may include a diameter ‘Di’ (e.g., between 2 and 10 inches, between 5 and 9 inches, between 4 and 8 inches, etc.) that may be greater than a diameter of the outlet of the respective secondary duct 26. Accordingly, the mounting plate 100 may be disposed over the outlet of the secondary duct 26. In some embodiments, the opening 102 of the mounting plate 100 may be sealed to the secondary duct 26 to form a substantially air-tight seal. For example, the mounting plate 100 may be welded to the secondary duct 26 and / or secured to the secondary duct 26 using an adhesive, a fastener, a clamp, and / or another suitable device. In other embodiments, the diameter Di may be less than or equal to the diameter of the outlet of the respective secondary duct 26. In such embodiments, the mounting plate 100 may be coupled to the secondary duct 26using an intermediate component (e.g., a fitting that couples tubulars of different diameters). In other words, the mounting plate 100 is configured to be fluidly coupled to the ductwork 14 via the opening 102.

[0048] In some embodiments, the body 101 of the mounting plate 100 may further include a center portion 104, which may include the opening 102. The body 101 of the mounting plate 100 may further include a wall portion 106 that is coupled to the center portion 104 and extends away from the opening 102. The body 101 of the mounting plate 100 may further include a plurality of edges 108 such that the wall portion 106 is provided between the plurality of edges 108 and the center portion 104. In other words, the wall portion 106 has a first end coupled to the center portion 104 and a second end coupled to the plurality of edges 108. The wall portion 106 may include recessed walls 110 (e g., angled walls) that extend between the edges 108 and the center portion 104 of the mounting plate 100. The center portion 104 may refer to a substantially planar structural portion of the mounting plate 100 that extends between the recessed walls 110.Further, the recessed walls 110 (e.g., angled walls) may be angled outwards, creating an obtuse angle with the center portion 104. As shown in the illustrated embodiment, an end of each recessed wall 110 coupled to the center portion 104 is shorter than opposite end couped to the edges 108.

[0049] In some embodiments, the recessed walls 110 may be tapered along wall mating edges 112 formed at corners 114 of the mounting plate 100. Tapering the recessed walls 110 may facilitate diffusion of the conditioned air towards the interior space. For example, tapering the recessed walls 110 may reduce a resistance to the flow of the conditioned air caused by the recessed walls 110. Accordingly, the recessed walls 110 may enhance an efficiency of an air diffuser, coupled to the mounting plate 100, by facilitating flow of the conditioned air into the interior space. In some embodiments, the mounting plate 100 may include a metallic material, such as steel and / or aluminum. In other embodiments, the mounting plate 100 may include another suitable material, such as a ferrous metal or plastic (e.g., a polymeric material).

[0050] As shown in the illustrated embodiment, the recessed walls 110 include tapered portions 116 along the wall mating edges 112 formed at the comers 114 of the mounting plate 100. The tapered portions 116 may reduce resistance caused by the mounting plate 100 to the conditioned air flowing into the interior space. Additionally, the tapered portions 116 may guide the conditioned air along a desired flow path into the interior space (e.g., toward an opening in the air diffuser). Though the mounting plate 100 is shown to include tapered portions 116, the scope of the disclosure is not limited to it. In some other embodiments, instead of having the tapered portions 116, the mounting plate 100 may include rounded portions at the wall mating edges 112 without deviating from the scope of the disclosure.

[0051] In some embodiments, the recessed walls 110 may include a contoured surface that may facilitate flow of the conditioned air in addition to the tapered portions 116. For example, the contoured surface may include a curvature that decreases a resistance caused by the recessed walls 110 on the flow of conditioned air, thereby increasing a flow of the conditioned air into the interior space.

[0052] In some embodiments, each edge 108 may include a lip that is configured to allow mounting in a narrow tee or tegular suspended ceiling grid module. Additionally, the edges 108 of the mounting plate 100 may be substantially flush with a mounting surface (e.g., a ceiling, a floor, a wall, an exposed duct, etc.) of the interior space. In some embodiments, the recessed walls 110 may extend into the ceiling and toward the secondary duct 26. Accordingly, the center portion 104 may be offset from, but substantially parallel to, the mounting surface of the interior space.

[0053] The body 101 of the mounting plate 100 may further include a plurality of mating features to make a plurality of air diffuser configurations compatible with the mounting plate 100. Each mating feature may be configured to support mounting of an air diffuser of a distinct air diffuser configuration. Examples of different air diffuser configurations may include, but are not limited to, swirl diffusers, cone diffusers, plaque diffusers, perforated diffusers, or the like.

[0054] In some embodiments, the mounting plate 100 may include one or more slots 118 provided on the center portion 104. In an example, the slots 118 are hook slots. The mounting plate 100 may further include one or more weld projections 120 provided on the center portion 104 to mark one or more welding sites. The weld projections 120 may refer to projected features, (for example, bumps, studs, or the like) provided on the center portion 104 to allow concentration of heat and electrical current during a welding process. Further, the weld projections 120 are provided to create localized points of contact for welding. The slots 118 and the weld projections 120 may correspond to the plurality of mating features such that the slots 118 support mounting of an air diffuser having a first air diffuser configuration and the weld projections 120 support mounting of another air diffuser having a second air diffuser configuration, with the mounting plate 100. Here, the first air diffuser configuration is different from the second air diffuser configuration. For example, the air diffuser having the first air diffuser configuration may be a plaque diffuser and the air diffuser having the second air diffuser configuration may be a cone diffuser.

[0055] Further, the edges 108 may function as one of the plurality of mating features for coupling an air diffuser having a third air diffuser configuration with the mounting plate 100. In an example, the air diffuser having the third air diffuser configuration may be a perforated diffuser. Furthermore, the wall portion 106 (more specifically, the tapered portions 116) of the mounting plate 100 may also function as one of the plurality of mating features for coupling an air diffuser having a fourth air diffuser configuration with the mounting plate 100. In an example, the air diffuser having the fourth air diffuser configuration may be a swirl diffuser.

[0056] Though FIG. 2 describes four types of mating features provided on the mounting plate 100 to support mounting of plaque diffusers, cone diffusers, perforated diffusers, and swirl diffusers, the scope of disclosure is not limited to it. The mounting plate 100 can additionally include other suitable mating features that allow air diffusers of other suitable configurations to be mounted using the mounting plate 100. Operative details for mounting air diffusers of a plurality of configurations using the mounting plate 100 are described later in detail in conjunction with FIGS. 3A-6D.Air diffusers compatible with universal mounting plate

[0057] FIG. 3A is a diagram that illustrates an air diffuser assembly 200, according to a first embodiment of the present disclosure. FIG. 3B is a diagram that illustrates a partial cross- sectional side view of the air diffuser assembly 200 along line A- A, in accordance with the first embodiment of the present disclosure.

[0058] Referring now to FIGS. 3A and 3B, the air diffuser assembly 200 may include the mounting plate 100 and a diffusion plate 202 (e.g., an air diffuser of first air diffuser configuration). In other embodiments, the air diffuser assembly 200 may include other suitable components (for example, a flow adapter) required for efficient operations of the air diffuser assembly 200, without deviating from the scope of the disclosure.

[0059] The air diffuser assembly 200 may be secured around an outlet 203 of the secondary duct 26. In some embodiments, the outlet 203 may extend into the opening 102 of the mounting plate 100 and be secured to the mounting plate 100, for example, via a weld, a fastener (e.g., bolts, screws, clamps, etc.), an adhesive, and / or another securement device.

[0060] The diffusion plate 202 may be positioned below the mounting plate 100 with respect to a mounting surface 204 of the interior space. In some embodiments, the diffusion plate 202 may be coupled to the mounting plate 100 so that a gap 206 is provided between the diffusion plate 202 and the mounting plate 100. In other words, the diffusion plate 202 may extend beyond the mounting plate 100 by a distance indicated by the gap 206. In some other embodiments, the diffusion plate 202 may extend into the mounting plate 100.

[0061] The diffusion plate 202 may be coupled to the mounting plate 100 using one or more brackets 208 that extend into the slots 118 (e.g., one of the plurality of mating features provided on the mounting plate 100) of the mounting plate 100. In some embodiments, the brackets 208 may be welded onto the diffusion plate 202 and / or otherwise secured to the diffusion plate 202. In other embodiments, the diffusion plate 202 may be secured to the mounting plate 100 using another suitable fastener (e.g., threaded bolts, screws, etc.) via the slots 118.

[0062] The slots 118 of the mounting plate 100 are configured to receive the brackets 208 that couple the diffusion plate 202 to the mounting plate 100. In some embodiments, the slots 118 may extend through the mounting plate 100 such that the brackets 208 may extend through the mounting plate 100 and secure to the mounting plate 100 using a fastener (e.g., a hook) and / or an adhesive. As shown in the illustrated embodiment of FIG. 3B, the diffusion plate 202 is coupled to the mounting plate 100 via the brackets 208 that extend through the slots 118 in the mounting plate 100. The brackets 208 are shown to include hooks 209 that are configured to secure the brackets 208 in the slots 118. For example, the hooks 209 may contact an outer surface of the center portion 104 to block movement of the diffusion plate 202 with respect to the mounting plate 100. As shown in the illustrated embodiment of FIGS. 3A and 3B, the diffusion plate 202 is a plaque diffuser (e.g., the first air diffuser configuration) mounted to the mounting plate 100 using the slots 118 while remaining plurality of mating features (e.g., the weld projections 120, the edges 108, the wall portion 106, etc.) remain unused for mounting purposes.

[0063] In some embodiments, the diffusion plate 202 may include the same material as the mounting plate 100. For example, the diffusion plate 202 may include steel, aluminum, and / or another suitable material (e.g., a polymeric material). In other embodiments, the diffusion plate 202 may include a material different from the mounting plate 100.

[0064] Conditioned air may flow through the outlet 203 and into a chamber formed between the mounting plate 100 and the diffusion plate 202. As pressure builds within the chamber, the conditioned air may flow out of the chamber and into the interior space through openings 210 formed between the mounting plate 100 and the diffusion plate 202. The diffusion plate 202 may direct the flow of conditioned air towards the edges 108 of the mounting plate 100. By directing the flow of conditioned air toward the edges 108, the diffusion plate 202 may cause the conditioned air to adhere to mounting surface plane to engage in horizontal air flow, which may result in enhanced throw of the conditioned air into the interior space. Additionally, or alternatively, the diffusion plate 202 may increase a radius of the flow of conditioned air into the interior space than would otherwise occur without the diffusion plate 202. Accordingly,including the diffusion plate 202 spreads the flow of conditioned air, such that heating, cooling and / or ventilating the interior space is performed with increased efficiency.

[0065] FIG. 4A is a diagram that illustrates an air diffuser assembly 300, according to a second embodiment of the present disclosure. FIG. 4B is a diagram that illustrates an isometric view of the air diffuser assembly 300, in accordance with the second embodiment of the present disclosure.

[0066] Referring now to FIGS. 4A and 4B, the air diffuser assembly 300 may include the mounting plate 100 and a diffusion plate 302 (e.g., an air diffuser of second air diffuser configuration). In other embodiments, the air diffuser assembly 300 may include other suitable components (for example, a flow adapter) required for efficient operations of the air diffuser assembly 300, without deviating from the scope of the disclosure.

[0067] The air diffuser assembly 300 may be secured around an outlet of the secondary duct 26. In some embodiments, the outlet may extend into the opening 102 of the mounting plate 100 and be secured to the mounting plate 100, for example, via a weld, a fastener (e.g., bolts, screws, clamps, etc.), an adhesive, and / or another securement device.

[0068] The diffusion plate 302 may be positioned below the mounting plate 100 with respect to a mounting surface 304 of the interior space. In some embodiments, the diffusion plate 302 may be coupled to the mounting plate 100 so that a gap is provided between the diffusion plate 302 and the mounting plate 100. In some other embodiments, the diffusion plate 302 may extend into the mounting plate 100.

[0069] The diffusion plate 302 may be coupled to the mounting plate 100 via welding at the weld projections 120 (e.g., one of the plurality of mating features provided on the mounting plate 100) of the mounting plate 100. As shown in the illustrated embodiment of FIGS. 4A and 4B, the diffusion plate 302 is a cone diffuser having a plurality of cones 306A and 306B. Lower most cone 306A (for example, a cone that is proximal to the mounting plate 100) is welded to the mounting plate 100 at the weld projections 120 for mounting the diffusion plate 302. As thediffusion plate 302, having the second air diffuser configuration, is mounted to the mounting plate 100 using the weld projections 120, remaining plurality of mating features (e.g., the slots 118, the edges 108, the wall portion 106, etc.) remain unused for mounting purposes.

[0070] In some embodiments, the diffusion plate 302 may include the same material as the mounting plate 100. For example, the diffusion plate 302 may include steel, aluminum, and / or another suitable material (e.g., a polymeric material). In other embodiments, the diffusion plate 302 may include a material different from the mounting plate 100.

[0071] Conditioned air may flow through the outlet and into a chamber formed between the mounting plate 100 and the diffusion plate 302. As pressure builds within the chamber, the conditioned air may flow out of the chamber and into the interior space through openings 308, 310 formed between the mounting plate 100 and the diffusion plate 302.

[0072] FIGS. 5A and 5B are diagrams that illustrate an air diffuser assembly 400, according to a third embodiment of the present disclosure. In FIG. 5 A, a first face of the air diffuser assembly 400 is shown that faces a mounting surface of the interior space. In FIG. 5B, a second face of the air diffuser assembly 400 is shown that faces the interior space.

[0073] Referring now to FIGS. 5A and 5B, the air diffuser assembly 400 may include the mounting plate 100, a diffusion plate 402 (e.g., an air diffuser of third air diffuser configuration), a deflector plate 404, and a frame 406.

[0074] The deflector plate 404 may be coupled to the mounting plate 100 such that the deflector plate 404 substantially covers the opening 102, thereby directing all or a portion of the conditioned air that flows from the respective secondary duct 26 through the deflector plate 404. For example, in some embodiments, the deflector plate 404 may be coupled to the mounting plate 100 by a plurality of fasteners. The fasteners may extend through the deflector plate 404 and into the mounting plate 100. In some embodiments, the fasteners may be secured to the mounting plate 100 by nuts and / or other securement devices (e.g., threaded openings in the mounting plate 100). In some embodiments, the mounting plate 100 may include one or moreapertures configured to receive the fasteners that secure the deflector plate 404 to the mounting plate 100. In some embodiments, the apertures may include threads that are configured to secure the fasteners to the mounting plate 100. In other embodiments, the apertures may extend through the mounting plate 100, such that nuts and / or other securement devices may couple the deflector plate 404 to the mounting plate 100. When secured to the mounting plate 100, the deflector plate 404 may contact the center portion 104 of the mounting plate 100.

[0075] In some embodiments, the deflector plate 404 may be formed from a single piece of sheet material (e.g., steel sheet metal, aluminum sheet metal, and / or plastic). In other embodiments, the deflector plate 404 may be formed from an injection mold, and thus include a plastic material (e.g., a polymeric material). In still further embodiments, the deflector plate 404 may be formed from multiple pieces of sheet metal (e.g., steel and / or aluminum) and / or other materials (e.g., polymeric materials).

[0076] The diffusion plate 402 may be positioned below the deflector plate 404 with respect to the mounting surface of the interior space, such that the deflector plate 404 is positioned between the mounting plate 100 and the diffusion plate 402. The diffusion plate 402 may include a plurality of hemmed edges 408 configured to slidably engage with the plurality of edges 108 of the mounting plate 100 for mounting the diffusion plate 402 to the mounting plate 100. For example, each hemmed edge 408 provides a channel or a groove into which a corresponding edge 108 of the mounting plate 100 slides. In an embodiment, three of four edges of the diffusion plate 402 may be hemmed.

[0077] The diffusion plate 402 may further include a perforated section 410. In some embodiments, the perforated section 410 may be provided at a center of the diffusion plate 402 such that the perforated section 410 substantially covers the opening 102 and the deflector plate 404, thereby allowing the conditioned air to flow therethrough into the interior space.

[0078] The frame 406 may be coupled to the plurality of hemmed edges 408 of the diffusion plate 402 to secure the slidable engagement of the plurality of hemmed edges 408 with the plurality of edges 108 of the mounting plate 100. In other words, the frame 406 may beconfigured to substantially surround an entire perimeter of the diffusion plate 402 to enhance the structural integrity and to improve the aesthetics of the air diffuser assembly 400. Assembling process of the air diffuser assembly 400 is described in detail in conjunction with FIGS. 5C and 5D.

[0079] FIGS. 5C and 5D are diagrams that illustrate scenarios for mounting the air diffuser assembly 400, according to the third embodiment of the present disclosure. For the sake of brevity and illustration, the mounting plate 100 is shown to be a planar structure in FIGS. 5C and 5D.

[0080] Referring now to FIG. 5C, the deflector plate 404 is shown to be coupled to the mounting plate 100 and disposed over the opening 102 to substantially cover the opening 102. Further, the diffusion plate 402 is being slid to cover the mounting plate 100. As shown, the edges 108 of the mounting plate 100 are being slid in the hemmed edges 408 of the diffusion plate 402 for coupling the diffusion plate 402 to the mounting plate 100.

[0081] Referring now to FIG. 5D, upon successful coupling of the diffusion plate 402 with the mounting plate 100, the frame 406 is securely coupled to subassembly 412 of the diffusion plate 402 and the mounting plate 100. The frame 406 may create a closed rigid enclosure around the subassembly 412, preventing any lateral or unwanted movement. In other words, the frame 406 effectively “locks” the engagement between the diffusion plate 402 and the mounting plate 100. The frame 406 further provides a protection to the hemmed edges 408 from potential damage and also prevents leakage of air flow via any gaps that remain between the hemmed edges 408 of the diffusion plate 402 and the edges 108 of the mounting plate 100.

[0082] As can be seen in FIG. 5A-5D, the diffusion plate 402, having the third air diffuser configuration, is mounted to the mounting plate 100 using the edges 108 (e.g., one of the plurality of mating features) of the mounting plate 100. Thus, remaining plurality of mating features (e.g., the slots 118, the weld projections 120, the wall portion 106, etc.) remain unused for mounting purposes.

[0083] FIGS. 6A and 6B are diagrams that illustrate an air diffuser assembly 500, according to a fourth embodiment of the present disclosure. Referring now to FIGS. 6A and 6B, the air diffuser assembly 500 may include the mounting plate 100 and an air diffuser 502 (e.g., an air diffuser of fourth air diffuser configuration). In other embodiments, the air diffuser assembly 500 may include other suitable components (for example, a flow adapter) required for efficient operations of the air diffuser assembly 500, without deviating from the scope of the disclosure.

[0084] The air diffuser assembly 500 may be secured on a mounting surface 504 around an outlet of the secondary duct 26 (as shown in FIG. 1). In some embodiments, the outlet may extend into the opening 102 of the mounting plate 100 and be secured to the mounting plate 100, for example, via a weld, a fastener (e.g., bolts, screws, clamps, etc.), an adhesive, and / or another securement device.

[0085] The air diffuser 502 may include a base portion 506 and a plurality of walls 508 extending from the base portion 506. In some embodiments, the plurality of walls 508 may extend orthogonally from the base portion 506. The base portion 506 may include a plurality of openings 510 to allow conditioned air to flow into the interior space. In some embodiments, the openings 510 may have a circular or spiral arrangement to induce a swirling or rotational motion to the air as it is discharged into the interior space. Additionally, the base portion 506 may include guide vanes 512 that control a direction and spread of the air flow. In some embodiments, the guide vanes 512 may be adjustable within the openings 510 to adjust direction and spread of the air flow.

[0086] The air diffuser 502 may be positioned below the mounting plate 100 with respect to the mounting surface 504 of the interior space such that the plurality of walls 508 surround the plurality of edges 108. Further, the plurality of edges 108 may abut a surface of the base portion 506 that faces the mounting plate 100.

[0087] The air diffuser 502 may further include a plurality of support members 514 that pass through the plurality of walls 508 of the air diffuser 502. In the enlarged cut section Vi in FIG. 6A, two support members 514 are shown that pass through (or penetrate) the walls 508 of the airdiffuser 502. In some embodiments, the support members 514 can be fasteners, such as screws, bolts, etc., that are inserted through the walls 508 of the air diffuser 502. In some other embodiments, the support members 514 can be other suitable protruding members that provide secure engagement. The support members 514 may securely engage with the wall portion 106 of the mounting plate 100 to couple the air diffuser 502 to the mounting plate 100. For example, the support members 514 may abut or penetrate the wall portion 106, for example, the tapered portions 116, to secure the connection of the air diffuser 502 with the mounting plate 100. As the air diffuser 502 is mounted to the mounting plate 100 using the wall portion 106 (e.g., one of the plurality of mating features) remaining plurality of mating features (e.g., the slots 118, the weld projections 120, the edges 108, etc.) remain unused for mounting purposes.

[0088] Thus, the present disclosure provides a universal backpan (e.g., the mounting plate 100) that is compatible with a plurality of air diffuser configurations, which reduces inventory management complications and production complexity.Configuration of Embodiments

[0089] The construction and arrangement of the systems and methods as shown in the various embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.). For example, the position of elements can be reversed or otherwise varied and the nature or number of discrete elements or positions can be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. The order or sequence of any process or method steps can be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and omissions can be made in the design, operating conditions and arrangement of the embodiments without departing from the scope of the present disclosure.

[0090] Although the figures show a specific order of method steps, the order of the steps may differ from what is depicted. Also, two or more steps can be performed concurrently or withpartial concurrence. Such variation will depend on the software and hardware systems chosen and on designer choice. All such variations are within the scope of the disclosure. Likewise, software implementations could be accomplished with standard programming techniques with rule based logic and other logic to accomplish the various connection steps, processing steps, comparison steps and decision steps.

Claims

CLAIMSWhat is claimed is:

1. A mounting plate, comprising: a body; and a plurality of mating features provided on the body to make a plurality of air diffuser configurations compatible with the mounting plate, each mating feature configured to support mounting of an air diffuser of a distinct air diffuser configuration.

2. The mounting plate of claim 1, wherein the body comprises a center portion having an opening, the mounting plate is configured to be fluidly coupled to a ductwork via the opening.

3. The mounting plate of claim 2, wherein the plurality of mating features comprise one or more slots and one or more weld projections.

4. The mounting plate of claim 3, wherein the one or more slots and the one or more weld projections are provided on the center portion of the body.

5. The mounting plate of claim 3, wherein the one or more slots support mounting of an air diffuser having a first air diffuser configuration and the one or more weld projections support mounting of another air diffuser having a second air diffuser configuration, the first air diffuser configuration being different from the second air diffuser configuration.

6. The mounting plate of claim 5, wherein the body further comprises a wall portion coupled to the center portion and extending away from the opening.

7. The mounting plate of claim 6, wherein the wall portion functions as one of the plurality of mating features to couple an air diffuser having a third air diffuser configuration with the mounting plate.

8. The mounting plate of claim 6, wherein the body further comprises a plurality of edges such that the wall portion is provided between the plurality of edges and the center portion.

9. The mounting plate of claim 8, wherein the plurality of edges function as one of the plurality of mating features.

10. The mounting plate of claim 9, wherein one or more edges of the plurality of edges are configured to couple with an air diffuser having a fourth air diffuser configuration.

11. An air diffuser assembly, comprising: a mounting plate comprising a center portion with an opening, a plurality of edges, and a wall portion with a first end coupled to the center portion and a second end coupled to the plurality of edges, wherein the mounting plate is configured to be fluidly coupled to ductwork via the opening; and a diffusion plate comprising a plurality of hemmed edges configured to slidably engage with the plurality of edges of the mounting plate to couple the diffusion plate to the mounting plate.

12. The air diffuser assembly of claim 11, further comprising a deflector plate coupled to the mounting plate and disposed over the opening.

13. The air diffuser assembly of claim 12, wherein the deflector plate is positioned between the mounting plate and the diffusion plate.

14. The air diffuser assembly of claim 11, further comprising a frame coupled to the plurality of hemmed edges to secure the slidable engagement of the plurality of hemmed edges with the plurality of edges of the mounting plate.

15. The air diffuser assembly of claim 11, wherein the diffusion plate includes a perforated section that covers the opening.

16. An air diffuser assembly, comprising: a mounting plate comprising a center portion with an opening, a plurality of edges, and a wall portion with a first end coupled to the center portion and a second end coupled to the plurality of edges, wherein the mounting plate is configured to be fluidly coupled to ductwork via the opening; and an air diffuser comprising a base portion and a plurality of walls extending from the base portion, wherein the air diffuser is positioned over the mounting plate such that the plurality of walls surround the plurality of edges, and wherein the air diffuser has a plurality of support members that securely engage with the wall portion to couple the air diffuser to the mounting plate.

17. The air diffuser assembly of claim 16, wherein the plurality of support members is a plurality of fasteners inserted into the plurality of walls.

18. The air diffuser assembly of claim 16, wherein the base portion includes a plurality of openings to allow conditioned air to flow therethrough.

19. The air diffuser assembly of claim 18, wherein the plurality of openings have a circular or spiral arrangement.

20. The air diffuser assembly of claim 18, wherein the base portion includes a guide vanes that control a direction of flow of the conditioned air.

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