Air distribution system with controllable dampers

Abstract

An HVAC system may include a refrigeration subsystem, a plurality of air ducts each containing a controllable damper, and a controller configured to adjust the damper to regulate airflow. Each damper may be implemented as a modular puck assembly including an actuator, gear system, and control electronics. Sensors such as temperature, occupancy, and pressure sensors may be placed within rooms and ducts to monitor environmental conditions. The controller may use the sensor data, room dimensional data, and external inputs to optimize airflow and energy usage. The HVAC system enables individualized control of airflow to different rooms and supports remote and automated operation. The HVAC system provides adaptive climate control and enhanced energy efficiency in both residential and commercial buildings.

Description

Attorney Docket No. 02017-2501819AIR DISTRIBUTION SYSTEM WITH CONTROLLABLE DAMPERSCROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to United States Provisional Patent Application No.63 / 663,747, filed June 25, 2024, the disclosure of which is hereby incorporated by reference in its entirety.STATEMENT REGARDING FEDERAL FUNDING

[0002] This invention was made with government support under Grant No. DE-SC0021875, awarded by the United States Department of Energy, Office of Science. The government has certain rights in the invention.FIELD OF THE INVENTION

[0003] The present disclosure is generally directed to HVAC systems with optimized controllable operation and air flow for improved energy efficiency.BACKGROUND OF THE INVENTION

[0004] Modern American homes have increasing performance demands placed on them. Homeowners expect their homes to be comfortable, healthy, durable, affordable, and energy efficient. In contrast, many utility providers increasingly experience insufficient electric generating capacity or output due to ever-increasing consumer demand for electricity. Increases in fuel costs and high energy usage at certain parts of the day or seasonally can further strain existing utility infrastructure, require utility providers to either purchase more energy output capacity, or force disruptions to service to select customer regions for potentially prolonged periods of time.

[0005] Heating and cooling commercial and residential buildings comprise a large portion of energy usage and resulting costs. Systems and methods of optimizing HVAC systems to reduce overall energy usage can result in extensive savings both for the utility providers and the residential and commercial customers. The present disclosure provides examples of systems and methods of use thereof to optimize the distribution of conditioned and ventilation air in buildings to substantially reduce energy consumption and cost.163K9943.DOCXAttorney Docket No. 02017-2501819BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the disclosure itself will be better understood by reference to the following descriptions of embodiments of the disclosure taken in conjunction with the accompanying drawings, wherein:

[0007] Fig. 1 is a diagram of an example of an HVAC system constructed in accordance with the principles of the present invention.

[0008] Fig. 2 is a perspective view of an example of an HVAC system constructed in accordance with the principles of the present invention.

[0009] Fig. 3 is an exploded assembly view of an example of a damper for an HVAC system constructed in accordance with the principles of the present invention.

[0010] Fig. 4a is an illustrative example of a controller interface for an HVAC system constructed in accordance with the principles of the present invention.

[0011] Fig. 4b is an illustrative example of a flow chart for operation of an HVAC system constructed in accordance with the principles of the present invention.

[0012] Fig. 5 is an exploded assembly view of an example of a damper for an HVAC system constructed in accordance with the principles of the present invention.

[0013] Fig. 6a is a perspective view of an example of a damper assembly for an HVAC system constructed in accordance with the principles of the present invention.

[0014] Fig. 6b is a section view of a puck retention clip of the damper assembly of Fig. 6a.

[0015] Fig. 7 is an exploded assembly view of an example of a damper installed for an HVAC system constructed in accordance with the principles of the present invention installed at the endpoint of a duct.

[0016] Fig. 8 is an exploded assembly view of an example of a damper for an HVAC system constructed in accordance with the principles of the present invention installed at the manifold.263K9943.DOCXAttorney Docket No. 02017-2501819DESCRIPTION OF THE INVENTION

[0017] The following description is provided to enable those skilled in the art to make and use the described embodiments contemplated for carrying out the invention. Various modifications, equivalents, variations, and alternatives, however, will remain readily apparent to those skilled in the art. Any and all such modifications, variations, equivalents, and alternatives are intended to fall within the spirit and scope of the present invention.

[0018] For purposes of the description hereinafter, the terms “upper”, “lower”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, “lateral”, “longitudinal”, and derivatives thereof shall relate to the concept as it is oriented in the drawing figures. However, it is to be understood that the concept may assume various alternative variations, except where expressly specified to the contrary. It is also to be understood that the specific devices illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the concept. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting.

[0019] The word “comprising” and “comprises”, and the like, does not exclude the presence of elements or steps other than those listed in any claim or the specification as a whole. In the present specification, “comprises” means “includes” and “comprising” means “including.”

[0020] As used herein, “at least one of’ is synonymous with “one or more of.” For example, the phrase “at least one of A, B, or C” means any one of A, B, or C, or any combination of any two or more of A, B, or C. For example, “at least one of A, B, and C” includes A alone; or B alone; or C alone; or A and B; or A and C; or B and C; or all of A, B, and C.

[0021] The term “at least” is synonymous with “greater than or equal to.” The terms “first”, “second”, and the like are not intended to refer to any particular order or chronology, but refer to different conditions, properties, or elements. As used herein, the singular form of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.

[0022] All numbers used in the specification and claims are to be understood as being modified in all instances by the term “about”. By “about” is meant within plus or minus twenty-five percent of the stated value. However, this should not be considered as limiting to any analysis of the values under the doctrine of equivalents.

[0023] Unless otherwise indicated, all ranges or ratios disclosed herein are to be understood to encompass the beginning and ending values and any and all subranges or subratios subsumed therein. For example, a stated range or ratio of “1 to 10” should be considered to include any363K9943.DOCXAttorney Docket No. 02017-2501819and all subranges or subratios between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges or subratios beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less. The ranges and / or ratios disclosed herein represent the average values over the specified range and / or ratio.

[0024] Reference is now made to Figs. 1-2 which show an HVAC system, generally indicated as 10. The HVAC system 10 may generally include or define a central air conditioning system with a refrigeration subsystem 12 operable or configured to transfer heat from air flowing through the HVAC system 10. The refrigeration subsystem 12 may generally include or define a closed loop system defining one or more passages for refrigerant fluid flow therethrough, and may include a compressor 14, a condenser 16, and an evaporator 18 in a refrigerant flow relationship. In one example of operation, the compressor 14 compresses a refrigerant vapor exiting the evaporator 18 into a high pressure and temperature vapor. This high pressure vapor refrigerant transfers heat to an external location (typically to outdoor ambient air) in the condenser 16 by condensing into a liquid. The condenser 16 may include, for example, one or more coils or tubes adapted to receive the high temperature refrigerant from the compressor 14. The liquid refrigerant then passes through an expansion device (not shown), such as a thermostatic expansion valve or a fixed orifice device, to transition to a low pressure two-phase refrigerant. This refrigerant then enters the evaporator 18, which may be in contact with one or more air flow ducts or conduits 20. The evaporator 18 absorbs heat from air circulated through the ducts 20 by a fan or blower 22 disposed in the HVAC system 10. Cooled air is then blown through the ducts 20 into rooms to be cooled. The evaporator 18 then discharges refrigerant through one or more conduits back to the compressor 14 for the cycle to repeat. In addition and / or alternatively to the refrigeration subsystem 12, the HVAC system 10 may include one or more heating elements or otherwise be in fluid communication with a heat source (such as a furnace, an electric resistance heater or otherwise, not shown) to provide heated air through the ducts 20 as otherwise disclosed herein, or the refrigerant loop may be operated in reverse as a heat pump.

[0025] Now referring to Fig. 3, the HVAC system 10 may include one or more dampers 24 in one or more of the ducts 20. Each damper 24 may be configured to be selectively adjusted to modulate the air flow characteristics through one or more sections of one or more of the ducts 20. In one non-limiting example, a damper 24 may be positioned in each duct 20 of the HVAC system 10 to enable individual and selective control of the air flow through each duct 20 of the HVAC system, and as a result, enable individual and selective control of the air flow into each room or region where a duct 20 terminates or exits. Each damper 24 may be 463K9943.DOCXAttorney Docket No. 02017-2501819positioned at one or more positions along a particular duct 20 to provide the features and benefits disclosed herein. In one non-limiting example, each damper 24 may be positioned adjacent to or in proximity to the evaporator 18, the fan 22, and / or a main manifold or air handler of the HVAC system 10. In another non-limiting example, each damper 24 may be positioned adjacent to or in proximity to an end point or exhaust region of a duct 20 adjacent to or in proximity to a room or region receiving conditioned air from the HVAC system 10. In another non-limiting example, each damper 24 may be positioned in-line with a duct 20 through the use of an in-line coupler.

[0026] Each damper 24 may generally include a damper blade 26 movably positioned within the air flow path defined by or created within each duct 20. In one example, the damper blade 26 may be pivotally mounted to an exterior surface or wall of the duct 20 such that the damper blade 26 is rotatable around an axis Al transverse to a longitudinal axis A2 of the duct 20. The damper blade 26 may have a predefined range of motion. In one non-limiting example, the damper blade 26 may have a range of motion of approximately 90 degrees with respect to the longitudinal axis, such that the damper blade 26 is positionable in a plurality of angular positions ranging from a first position where the damper blade 26 is substantially parallel to the longitudinal axis A2 (resulting in a minimum obstruction to air flow through the duct 20) to a second position where the damper blade 26 is substantially perpendicular to the longitudinal axis A2 (resulting in a maximum obstruction to airflow through the duct 20).

[0027] In one example, the damper blade 26 may be coupled to a drive axle 28 coupled to and / or extending through a portion of the sidewall of the duct 20. The damper 24 may include an actuator 30 coupled to the damper blade 26 and / or the drive axle 28 to selectively adjust an angular position of the damper blade 26 about the axis Al. The actuator 30 may include, for example, an electric servo motor, a stepper motor, a linear actuator, or any other controllable mechanism providing the features and benefits described herein. In one non-limiting aspect, the damper 24 may include or define a predefined minimum adjustment angle or movement of the damper blade 26. Such fine motor control may be a function of the size, mass, and / or other characteristic of the damper blade 26, drive axle 28, actuator 30, and / or duct 20. In on example, the minimum adjustment angle of the damper blade may be between approximately 1 degree to 5 degrees.

[0028] Now referring to Fig. 5, in another example, the damper 24 may be a modular puck 100 including a housing 102, a motor 104, a motor gear 106, a PCB assembly 108 including a printed circuit board 110 and structure 112, a damper blade 126, a damper gear 114, and a damper flag 116. The housing 102 includes a housing top 118 and housing bottom 120. The 563K9943.DOCXAttorney Docket No. 02017-2501819housing bottom 120 has at least one puck retention tab 122 for holding the modular puck 100 in place against pressure of airflow, or in an upside-down position. The puck retention tab 122 is configured to hold the modular puck 100 in place while allowing the modular puck 100 to be removed with the force of a human hand.

[0029] The motor 104, the motor gear 106, the PCB assembly 108, the damper gear 114, and the damper flag 116 are disposed within the housing bottom 120. When assembled, the housing top 118 is connected to the housing bottom 120 via screws 124 creating a protective casing around the motor 104, the motor gear 106, the PCB assembly 108, the damper gear 114, and the damper flag 116. The damper blade 126 includes a flat portion 128 to direct airflow and a shaft 130 to connect it to damper gear 114 and the damper flag 116. The damper gear 114 is fixed on the damper blade shaft 130. The damper blade shaft 130 is disposed in the damper flag 116 providing support and stability to the damper blade shaft 130 while allowing for the damper blade 126 to freely rotate. The motor gear 106 is fixed on the motor 104, and the damper gear 114 is mated with the motor gear 106. This allows the position of the damper blade 126 to be set via the motor 104 through the gearing 106, 114.

[0030] Figs. 6a and 6b show the modular puck 100 of Fig. 5 and a receiver 136. The receiver 136 is configured to receive the modular puck 100. Upon insertion into the receiver 136 the modular puck 100 is held in place by the puck retention tabs 122. The puck retention tab 122 includes a insertion face 152, a dwell face 154, and a retention face 156. The receiver 136 has a mating ridge 158 that engages with the puck retention tab 122. The mating ridge 158 has an angled bottom, flat side, and flat top. During the initial phase of insertion, the insertion face 152 contacts the top of mating ridge 158, the angle of the insertion face 152 causes the retention tab 122 to deflect allowing the modular puck 100 to begin to enter the receiver 136. During the next stage of insertion, the dwell face 154 is in contact with the mating ridge 158 maintaining the deflection of the puck retention tab 122. The dwell face 154 is essentially vertical. During the final stage of insertion, the mating ridge 158 passes the dwell face 154 allowing the puck retention tab 122 to snap into place. In this final stage, the retention face 156 is in contact with the angled bottom of the mating ridge 158. The angled engagement between the retention face 156 and the mating ridge 158 holds the modular puck 100 in place, while allowing the modular puck 100 to be removed with the force of a human hand. In one non-limiting example, the angle of the retention face 156 may be approximately 124.5° as measured from the dwell face 154. In another example, the angle of the retention face 156 may be between approximately 109.5° and approximately 139.5°.663K9943.DOCXAttorney Docket No. 02017-2501819

[0031] The modular puck 100 may be installed in one of several different assemblies. Now referring to Fig. 7, for example, if the damper 24 at the termination of the duct 20 the modular puck 100 may be installed in a dual duct sidewall boot assembly. The dual duct sidewall boot assembly includes a dual duct sidewall boot 134, at least one modular puck 100, and at least one receiver 136. A modular puck 100 is disposed in a receiver 136 and held in place by a puck retention tab 122. This creates a receiver subassembly. The receiver subassembly is in turn fixedly connected to the dual duct sidewall boot 134. The dual duct sidewall boot 134 is configured to receive two receiver subassemblies. The features and components disclosed herein enable the modular puck 100 to be accessed and removed from a front or non-duct side of the boot assembly, allowing it to be replaced and repaired from the dwelling area without disassembling the receiver subassembly.

[0032] Now referring to Fig. 8, in another example, if the damper 24 is installed at the inlet of the duct 20 or at the manifold, the modular puck 100 may be installed in a takeoff assembly. The takeoff assembly includes a modular puck 100, a takeoff adapter 142, a takeoff 144, a duct board takeoff inner extender 146, and a duct board manifold 148. A hole 150 the size of the duct board takeoff inner extender 146 is in the duct board manifold 148. The duct board takeoff inner extender 146 is placed in the hole 150. The takeoff 144 is fixedly connected to the duct board takeoff inner extender 146. The modular puck 100 is disposed within the takeoff 144 and secured in place by the puck retention tabs 122. The takeoff adapter 142 is placed over the takeoff 144 and held in place by a removable clip, creating an airtight seal around the edge of the takeoff adapter 142 and the top of the modular puck housing 102. The takeoff adapter 142 is configured to be connected to the ducts 20. This assembly may also be attached directly to sheet metal or other duct materials using fasteners, adhesives or other attachment means.

[0033] Referring again to Fig. 1, the HVAC system 10 may include one or more sensors disposed on or about one or more components of the HVAC system 10 and / or in proximity to one or more rooms or regions receiving conditioned air form the HVAC system. The one or more sensors may be configured to record, detect, or otherwise an operating parameter affected by or involving the operation of the HVAC system, and communicate the recorded, detected parameter to the HVAC system 10 for potential modification of the operation thereof.

[0034] In one example, the HVAC system 10 may include one or more temperature sensors 32 disposed on or about one or more components of the HVAC system 10 and / or in proximity to one or more rooms or regions receiving conditioned air from the HVAC system 10.

[0035] In one example, the HVAC system 10 may include one or more occupancy sensors 34 disposed in proximity to one or more rooms or regions receiving conditioned air from the 763K9943.DOCXAttorney Docket No. 02017-2501819HVAC system 10. The one or more occupancy sensors 34 may include, for example, a motion sensor and / or a manual switch or input component indicating the use and occupancy of a room or region receiving conditioned air from the HVAC system 10.

[0036] In one example, the HVAC system 10 may include one or more pressure sensors 36 disposed on or about one or more components of the HVAC system 10 and / or in proximity to one or more rooms or regions receiving conditioned air from the HVAC system 10. The one or more pressure sensors 36 may, for example, be disposed in one or more of the ducts 20 to detect a static air pressure within the HVAC system 10 to prevent or indicate an operating condition exceeding desired air flow or pressure characteristics within the HVAC system 10. Each of the sensors disclosed herein may be implemented or combined with any one or more of the other sensors or components described herein.

[0037] The HVAC system 10 may include a controller 38 operable and configured to modulate, operate, and / or adjust the operation of one or more components of the HVAC system 10. The controller 38 may be in communication with and / or coupled to one or more of the components of the HVAC system 10, including but not limited to the refrigeration subsystem 12, the fan 22, the dampers 24, and / or one or more of the sensors 32, 34, 36.

[0038] The controller 38 may include one or more electronic components to enable and facilitate the features and benefits disclosed herein, including but not limited to one or more of a bus, processor, memory, storage component, input component, output component, and / or communication interface. In some non-limiting embodiments or aspects, the controller 38 may be implemented in hardware, firmware, or a combination of hardware and software. For example, the controller 38 may include a processor (e.g., a central processing unit (CPU), a graphics processing unit (GPU), an accelerated processing unit (APU), etc.), a microprocessor, a digital signal processor (DSP), and / or any processing component (e.g., a field-programmable gate array (FPGA), an application- specific integrated circuit (ASIC), etc.) that can be programmed to perform a function. A memory component of the controller 38 may include random access memory (RAM), read only memory (ROM), and / or another type of dynamic or static storage device (e.g., flash memory, magnetic memory, optical memory, etc.) that stores information and / or instructions for use by the controller 38. A storage component of the controller 38 may store information and / or software related to the operation and use of the controller 38 and / or HVAC system 10. For example, the storage component may include a hard disk (e.g., a magnetic disk, an optical disk, a magneto-optic disk, a solid state disk, etc.) and / or another type of computer-readable medium.863K9943.DOCXAttorney Docket No. 02017-2501819

[0039] An input component of the controller 38 may include a component that permits the controller 38 to receive information, such as via user input (e.g., a touch screen display, a keyboard, a keypad, a mouse, a button, a switch, a microphone, etc.). Additionally or alternatively, the input component of the controller 38 may include a sensor for sensing information (e.g., a global positioning system (GPS) component, an accelerometer, a gyroscope, an actuator, etc.). An output component of the controller 38 may include a component that provides output information from the controller 38 and / or the HVAC system 10 (e.g., a display, a speaker, one or more light-emitting diodes (LEDs), etc.).

[0040] A communication interface of the controller 38 may include a transceiver- like component (e.g., a transceiver, a separate receiver and transmitter, etc.) that enables the controller 38 and / or HVAC system 10 to communicate with other devices, such as via a wired connection, a wireless connection, or a combination of wired and wireless connections. The communication interface may permit the controller 38 to receive information from another device and / or provide information to another device. For example, the communication interface may include an Ethernet interface, an optical interface, a coaxial interface, an infrared interface, a radio frequency (RF) interface, a universal serial bus (USB) interface, a Wi-Fi® interface, a cellular network interface, and / or the like.

[0041] The controller 38 may perform one or more processes described herein based on processor executing software instructions stored by a computer-readable medium, such as the memory and / or storage component described herein. A computer-readable medium (e.g., a non-transitory computer-readable medium) is defined herein as a non-transitory memory device. A memory device includes memory space located inside of a single physical storage device or memory space spread across multiple physical storage devices.

[0042] Software instructions may be read into the controller 38 from another computer-readable medium or from another device via the communication interface. When executed, software instructions stored in a memory and / or storage component may cause the controller 38 to perform one or more processes described herein. Additionally or alternatively, hardwired circuitry may be used in place of or in combination with software instructions to perform one or more processes described herein. Thus, embodiments or aspects described herein are not limited to any specific combination of hardware circuitry and software.

[0043] Now referring to Fig. 4a, the controller 38 may provide or include a schematic, diagram, blueprint, or other dimensional representation or model 40 of the building, region, or other defined space receiving conditioned air flow from the HVAC system 10. The model 40 may include the position, size, square footage, and / or volume of each room or discrete space 963K9943.DOCXAttorney Docket No. 02017-2501819within the building, region, or other defined space characterized by the model 40. Such information pertaining to and / or included with the model 40 may be considered or implemented by the controller 38 to adjust operation of one or more components of the HVAC system 10. In addition to a global temperature adjustment, the temperature in individual rooms may be selectively adjusted using a bias value (e.g. positive or negative) relative to a global temperature setting. The controller 38 may also be configured to enable manual or scheduled toggling of air flow to individual rooms. In such instances, the controller 38 is configured to reduce airflow to an individual room (e.g., fully, or partly reduced with a minimum amount of airflow to ensure the room condition is maintained at a minimum temperature and humidity value) and therefore reduce energy consumption.

[0044] In an exemplary method of use, the HVAC system 10 may be configured and positioned to distribute conditioned air flow to a plurality of rooms of a building. Data regarding dimensional or other features of each of the plurality rooms may be characterized by or associated with the model 40, as described herein. Each of the plurality of rooms may be coupled to or otherwise receive conditioned air flow from one or more ducts 20. Each of the one or more ducts 20 may include one or more dampers 24 controlled at least in part by the controller 38. Each of the plurality of rooms may include one or more of the temperature sensors 32 and / or the occupancy sensors 34. One or more of the ducts 20 to one or more of the plurality of rooms may include the pressure sensor 36.

[0045] Now referring to Fig. 4b, an exemplary method of use of the HVAC system 10 may include modifying the operation of one or more components of the HVAC system 10 in response to information and / or signals from the sensors disclosed herein to attain a target temperature. Such sensory information may include, for example, a detected temperature in a target room, occupancy of one or more targeted rooms, detected temperature in a room adjacent or in proximity to a targeted room, one or more dimensions or physical characteristics of a target room, one or more dimensions or physical characteristics of a room adjacent to or in proximity to a target room, or the like.

[0046] In one non-limiting example or aspect, a desired target temperature may be set and / or input into the controller 38 for each room of the plurality of rooms. The controller 38 may communicate with the temperature sensor 32 in each room, and in response to a detected temperature in a particular room, adjust the position of one or more of the dampers 24 in the ducts 20 providing conditioned air to the particular room to attain the preselected target temperature within that room.1063K9943.DOCXAttorney Docket No. 02017-2501819

[0047] In one example, the controller 38 may communicate with the temperature sensor 32 and occupancy sensor 34 of the room. In response to a detected temperature in a particular room, and if the room is not occupied as indicated by the occupancy sensor 34 or by user input , the controller 38 may refrain from adjusting the damper 24 or other aspect of the HVAC operation to allow the temperature in the room to rise above or to a predetermined threshold. For example, if the target temperature of a particular room is 72 degrees, and the temperature sensor detects a temperature above 72 degrees but the occupancy sensor 34 indicates nonoccupancy, then the controller 38 may raise the preselected target temperature a predetermined amount (e.g., 3-5 degrees or as desired) and / or allow a higher detected temperature to occur. Once the new controller-adjusted target temperature is reached and / or the occupancy sensor 34 indicates occupancy, the controller 38 may adjust the position of one or more of the dampers 24 in the ducts 20 providing conditioned air to the particular room to attain the preselected target temperature within that room. Conversely in heating mode, unoccupied rooms may have their target temperature lowered by a predetermined amount.

[0048] In one non-limiting example or aspect, the conditioned air flow provided by the HVAC system 10 to a first room may be adjusted at least in part on a condition or relative characteristic of a second room. For example, if the target temperature of a first room is 72 degrees, and the temperature sensor detects a temperature above 72 degrees, the controller 38 may analyze or compare the temperatures in one or more adjoining rooms to determine whether to adjust the position of one or more of the dampers 24 in the ducts 20 providing conditioned air to the first room to attain the preselected target temperature within that room. The controller 38 may additionally and / or alternatively analyze or take into account the size, square footage, and / or volume of the first room compared to size, square footage, and / or volume of one or more adjoining rooms to determine whether to adjust the position of one or more of the dampers 24. In one example, if the size, square footage, and / or volume of the first room is below a threshold percentage or relative value compared to size, square footage, and / or volume of one or more adjoining rooms, and the target temperature in the one or more adjoining rooms has been reached and / or maintained, then the controller 38 may raise the preselected target temperature in the first room a predetermined amount and / or allow a higher detected temperature to occur until the new target temperature in the first room is exceeded and / or the preselected temperature in the one or more adjoining rooms is exceeded.

[0049] In one non-limiting example or aspect, the controller 38 may calculate or otherwise ascertain a range of movement or angular adjustment of one or more dampers 24 (e.g., such as an angular position of the damper blade 26) in a particular duct 20 needed to provide a desired 1163K9943.DOCXAttorney Docket No. 02017-2501819air flow rate or volume through the duct 20 to efficiently achieve a targeted temperature in a room or region receiving conditioned air from the duct. The controller 38 may calculate or otherwise determine an appropriate adjustment of the one or more dampers 24 based at least in part on a difference between a target temperature and a detected or measured temperature within a room; a difference between a detected or measured temperature within a first room and a detected or measured temperature within a second room; an air pressure detected in one or more ducts 20 of the HVAC system 10; and / or an operating condition of one or more components of the refrigeration subsystem 12 and / or the fan 22. In one non-limiting example or aspect, if the calculated adjustment to an angular position of the damper blade 26 is below or less than a predetermined or predefined minimum adjustment angle of movement for the damper blade 26, the controller 38 may be programmed or configured to maintain a current position or status of the damper blade 26.

[0050] In one non-limiting example or aspect, the controller 38 may be configured or programmed to adjust operation of one or more components of the HVAC system 10 in addition to and / or alternatively to the dampers 24 to provide sufficient conditioned air flow to one or more regions to reach a target temperature or other. For example, the controller 38 may be configured or programmed to adjust a speed or RPM of the fan 22, a refrigerant flow rate through the refrigeration system 12, and / or other operational characteristics of the HVAC system 10.

[0051] The controller 38 may be configured or programmed to store data related to the operation of the HVAC system 10 over time. For example, the controller 38 may record information received from the various sensors disclosed herein as well as operating parameters of the HVAC system 10, such as angular position of the dampers 24 and / or speed or RPM of the fan 22. The recorded and stored data may be implemented to predict operating parameters and energy expenditure of future use during seasonal and temperature changes experienced by a building serviced by the HVAC system 10.

[0052] In one non-limiting example or aspect, the controller 38 may be configured or programmed to adjust operation of one or more components of the HVAC system 10 in addition to and / or alternatively to the dampers 24 in response to a detected or signaled peak grid event that may be indicative of an energy load on a utility power grid or network, an energy price signal, and / or a greenhouse gas emissions signal. For example, a utility provider may send a message or signal to the controller 38 alerting the controller 38 that a grid event and / or energy demand threshold has been met or triggered. When the grid event is triggered or indicated, the controller 38 may adjust operation of one or more components of the HVAC system 10 in 1263K9943.DOCXAttorney Docket No. 02017-2501819addition to and / or alternatively to the dampers 24 to adjust a target or realized temperature of one or more areas receiving air flow from the ducts 20.

[0053] In one non-limiting example, one or more rooms or regions of a building or structure serviced by the HVAC system 10 may be designated as either a “priority room” or a “nonpriority room.” When the grid event is indicated, the target temperature of the one or more non-priority rooms may be automatically adjusted to reduce energy demand, while the target temperature of the one or more priority rooms remains unadjusted. The selection or designation of priority or non-priority status for a region or area may be made by a user through a user interface for the controller, and / or may include selecting one or more regions from the graphical presentation of the model 40 as described herein.

[0054] In one non-limiting example, a peak grid event may be pre-scheduled or otherwise know ahead of time. In such instances, the controller 38 may be configured or programmed to adjust operation of one or more components of the HVAC system 10 in addition to and / or alternatively to the dampers 24 to pre-cool (or pre-heat) one or more priority or non-priority rooms to a modified target temperature prior to the grid event in anticipation of a reduced energy operational mode.

[0055] In the examples described above, in response to a signal or alert that a grid event has concluded, the controller 38 and / or other components of the HVAC system 10 may return to their normal operation as described herein. In one example, upon the indication that the grid event has concluded, the controller 38 may be configured or programmed to adjust operation of one or more components of the HVAC system 10 in addition to and / or alternatively to the dampers 24 to prioritize or increase air flow to the non-priority rooms to expedite attaining the regular target temperature of those rooms.

[0056] In another example, the controller 38, dampers 24, and / or other components of the HVAC system 10 may be connected to a multi-speed heat pump that can operate with different capacities. In response to a utility event or signal, the controller 38 may signal the heat pump to operate at a lower stage or speed to further conserve energy and direct all of the conditioned energy to just the priority rooms in the building. The controller 38 may also signal the heat pump to operate at a lower stage depending on the number of zones in the building that are calling for heating or cooling to save energy under normal operation. A non-limiting example of a signal to the heat pump may include a direct signal of a target percentage (or range) of maximum capacity to operate at, a rotational speed of the fan and compressor, and / or the controller 38 may adjust the current setpoint of a thermostat of the heat pump relative to a current measured temperature to adjust operation into a higher or lower output state.1363K9943.DOCXAttorney Docket No. 02017-2501819

[0057] Features of the present disclosure can be realized in hardware, software, or a combination of hardware and software. Any kind of computing system, or other apparatus adapted for carrying out the methods described herein, is suited to perform the functions described herein.

[0058] A typical combination of hardware and software could be a specialized or general purpose computer system having one or more processing elements and a computer program stored on a storage medium that, when loaded and executed, controls the computer system such that it carries out the methods described herein. Features of the present disclosure can also be embedded in a computer program product that comprises all the features enabling the implementation of the methods described herein, and which, when loaded in a computing system is able to carry out these methods. Storage medium refers to any volatile or non-volatile computer readable storage device such as magnetic storage, semiconductor memory, DVD, Compact Disk, or memory stick.

[0059] Computer program or application in the present context means any expression, in any language, code or notation, of a set of instructions intended to cause a system having an information processing capability to perform a particular function either directly or after either or both of the following a) conversion to another language, code or notation; b) reproduction in a different material form. Significantly, this invention can be embodied in other specific forms without departing from the spirit or essential attributes thereof, and accordingly, reference should be had to the following claims, rather than to the foregoing specification, as indicating the scope of the invention.

[0060] Program code may be transmitted to a computer constructed in accordance with the principles of the present disclosure using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.

[0061] Computer program code for carrying out operations for aspects of the present disclosure may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user’s computer, partly on the user's computer, as a stand-alone software package, partly on the user’s computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the1463K9943.DOCXAttorney Docket No. 02017-2501819connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).

[0062] Aspects of the present disclosure are described herein with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the disclosure. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions / acts specified in the flowchart and / or block diagram block or blocks.

[0063] These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function / act specified in the flowchart and / or block diagram block or blocks.

[0064] The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions / acts specified in the flowchart and / or block diagram block or blocks. It is noted that the computer programs of the present disclosure can be downloaded via the Internet to a computer, such as network device and / or target host system, having a TCP / IP-based network adapter card for installation in the computer.

[0065] It will be appreciated by persons skilled in the art that the present disclosure is not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. Of note, the system components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Moreover, while certain embodiments or figures 1563K9943.DOCXAttorney Docket No. 02017-2501819described herein may illustrate features not expressly indicated on other figures or embodiments, it is understood that the features and components of the examples disclosed herein are not necessarily exclusive of each other and may be included in a variety of different combinations or configurations without departing from the scope and spirit of the disclosure. A variety of modifications and variations are possible in light of the above teachings without departing from the scope and spirit of the disclosure, which is limited only by the following claims.1663K9943.DOCX

Claims

Attorney Docket No. 02017-2501819What is claimed is:

1. An HVAC system, comprising:a plurality of ducts configured to provide conditioned air flow to a plurality of rooms; a damper positioned within each of the plurality of ducts, each damper configured to modify an air flow rate through the duct;a refrigeration subsystem comprising a compressor, a condenser, and an evaporator or a heat source in thermal communication with the plurality of ducts;a fan configured to circulate conditioned air in the plurality of ducts; anda controller configured to adjust at least one damper in response to a detected condition.

2. The HVAC system of claim 1, wherein each of the plurality of rooms includes one or more sensors configured to provide input data to the controller.

3. The HVAC system of claim 1, wherein the detected condition is a measured temperature in at least one of the plurality of rooms.

4. The HVAC system of claim 1, wherein the detected condition is a measured temperature in a first room of the plurality of rooms, and wherein the controller adjusts a damper positioned in a duct providing conditioned air flow to a second room.

5. The HVAC system of claim 1, wherein the detected condition is a detected occupancy in at least one of the plurality of rooms.

6. The HVAC system of claim 1, wherein the controller includes stored dimensional information associated with the plurality of rooms, and wherein the controller is configured to adjust at least one damper based at least in part on the stored dimensional and construction characteristic information.

7. The HVAC system of claim 1, wherein the detected condition is a measured pressure in at least one of the plurality of ducts.

8. The HVAC system of claim 1, wherein the controller is configured to store information associated with a plurality of detected conditions over a predetermined period of time.1763K9943.DOCXAttorney Docket No. 02017-25018199. The HVAC system of claim 1, wherein the controller is configured to adjust the operation of one or more components of the HVAC system based on a peak grid event, an energy price signal, or a greenhouse gas emissions signal.

10. The HVAC system of claim 1, wherein the controller is configured to prioritize air flow to at least one of the plurality of rooms based on a predefined schedule or an external command.

11. The HVAC system of claim 1, wherein the controller is configured to adjust airflow to a first room based on a measured temperature in an adjacent room.

12. The HVAC system of claim 1, wherein the controller is configured to provide a dimensional representation of the plurality of rooms, the dimensional representation including a schematic, diagram, blueprint, or model showing the position, size, square footage, and / or volume of each of the plurality of rooms, andwherein the controller is further configured to use the dimensional representation to adjust operation of one or more components of the HVAC system.

13. The HVAC system of claim 1, wherein the controller further comprises a communication interface to enable remote operation of the HVAC system through a user device.

14. The HVAC system of claim 1, wherein the damper further comprises:a damper blade movably positioned within an airflow path defined by each duct of the plurality of ducts, the damper blade pivotally mounted to an exterior surface of the duct such that the damper blade is rotatable around an axis transverse to a longitudinal axis of the duct;a drive axle coupled to the damper blade and extending through a portion of a sidewall of the duct; andan actuator coupled to the damper blade and / or the drive axle, the actuator configured to selectively adjust an angular position of the damper blade about the axis.

15. The HVAC system of claim 1, wherein the damper comprises a modular puck, the modular puck including:1863K9943.DOCXAttorney Docket No. 02017-2501819a housing defining an enclosure, the housing including a housing top connected to a housing bottom, the housing bottom further including at least one puck retention feature for holding the modular puck in place within each duct of the plurality of ducts;an actuator;a PCB assembly, the PCB assembly including a printed circuit board and a structure;anda damper blade, the damper blade including a flat portion to direct airflow and a shaft; wherein the actuator, and the PCB assembly are disposed within the housing.

16. The HVAC system of claim 15, further comprising:an actuator gear;a damper gear;a damper flag; anda receiver configured to receive the modular puck;wherein the actuator gear, the damper gear, and the damper flag are disposed within the housing,the damper gear is fixed on the shaft,the shaft of the damper blade is disposed in the damper flag, allowing the damper blade to rotate freely,the actuator gear is fixed on the actuator, andthe damper gear is mated with the actuator gear.

17. A method for controlling the operation of an HVAC system, the method comprising:selecting a target room of a plurality of rooms;setting a target temperature for the target room;receiving data from a plurality of sensors positioned within the target room; adjusting one or more components of the HVAC system through a controller in response to the data received from the plurality of sensors to attain the target temperature.

18. The method for controlling the operation of an HVAC system of claim 17, wherein the controller is configured to communicate with a temperature sensor in each of the plurality of rooms, and1963K9943.DOCXAttorney Docket No. 02017-2501819wherein in response to a detected temperature in the target room, the controller is configured to adjust a position of one or more dampers provided in a plurality of ducts of the HVAC system to provide conditioned air to the target room to attain the target temperature.

19. The method for controlling the operation of an HVAC system of claim 18, wherein airflow to the target room is adjusted based on a condition of a second room.

20. The method for controlling the operation of an HVAC system of claim 17, wherein the controller is configured to communicate with a temperature sensor and an occupancy sensor in each of the plurality of rooms, andwherein, in response to a detected temperature in the target room and an occupancy condition indicating that the target room is unoccupied, the controller is further configured to adjust the target temperature to maintain a reduced level of airflow to the target room.

21. The method for controlling the operation of an HVAC system of claim 20, wherein the occupancy condition is set by a user input.2063K9943.DOCX

Images