Universal diffuser assembly and method of manufacturing

Claim 2

In a diffuser assembly for connection to an air delivery system the improvement comprising; a plenum chamber having a base connector member and an outwardly extending wall defining an approximately concave configuration, the wall and connector member formed from molded glass fibers and plastic binders to provide a cross-sectional configuration having an interior fibrous textured surface and a comparatively more densely fibrous packed exterior housing surface to provide a lightweight sound absorbing diffuser assembly, the total density of the base connector member being less than the total density of the wall whereby the wall is provided with greater structural strength while the base connector member has greater insulation and sound absorbing capabilities, and means for connecting the plenum chamber to the air delivery system.

Claim 3

The invention of claim 1 wherein the molded glass fibers and uncured plastic binders are compacted in an appropriately shaped mold and are cured at approximately temperatures representative of temperatures of 700° F. to 900° F. for a time period of approximately 25 to 45 seconds for a connector member thickness of approximately one-fourth inch to provide the interior fibrous textured surface.

Claim 4

The invention of claim 2 wherein carbon black is mixed with the uncured plastic binder on the interior surface before curing.

Claim 5

The invention of claim 3 wherein a plurality of layers of fiberglass and uncured phenolic binders are compression molded together under a pressure of approximately 2.5 tons per square foot.

Claim 6

The invention of claim 4 wherein an intermediate sheet of non-curable material is positioned between at least two layers of fiberglass and uncured phenolic binders.

Claim 7

The invention of claim 4 wherein the base connector member has a plurality of indented concentric configurations to permit the diffuser assembly to be universally adaptable to various duct sizes by removing a selected concentric configuration compatible with the interfacing duct.

Claim 8

The invention of claim 1 wherein the interior fibrous textured surface includes an inert filler to provide fibrous glass fibers extending freely from the interior surface.

Claim 9

The invention of claim 1 wherein an intermediate sheet is positioned between at least two layers of fiberglass and plastic binders to reduce any porosity of the plenum chamber and the plenum chamber consists of only the glass fibers plastic binder and intermediate sheet.

Claim 10

A diffuser assembly for connection to an air delivery system with ducts comprising; a plenum chamber member including a base connector and a wall extending from the base connector to define the plenum chamber cavity, the wall and base connector integrally formed from compressed laminae of glass fibers and plastic binders to provide a lightweight, thermal insulating, sound absorbing plenum chamber member having an interior fibrous textured surface and a comparatively more densely packed fibrous exterior laminae surface, further the total density of at least a portion of the wall being greater than the total density of the base connector member to provide structural strength to the plenum chamber member while the less dense base connector increases the sound absorbing capabilities; means for forming an aperture in the base connector for interconnection with a duct of the air delivery system; a perforated faceplate connected to the plenum chamber member to close at least a portion of the plenum chamber cavity and means for controlling the directional flow pattern of air through the faceplate.

Claim 11

A diffuser assembly for connection to an air delivery system with ducts comprising; a plenum chamber member including a base connector and a wall extending from the base connector to define the plenum chamber cavity, the wall and base connector integrally formed from compressed laminae of glass fibers and plastic binders to provide a lightweight, thermal insulating, sound absorbing plenum chamber member having an interior fibrous textured surface and a comparatively more densely packed fibrous exterior laminae surface, further the total density of at least a portion of the wall being greater than the total density of the base connector member to provide structural strength to the plenum chamber member while the less dense base connector increases the sound absorbing capabilities; means for forming an aperture in the base connector for interconnection with a duct of the air delivery system; a perforated faceplate connected to the plenum chamber member to close at least a portion of the plenum chamber cavity and means for controlling the directional flow pattern of air through the faceplate.

Claim 12

The invention of claim 9 wherein the means for forming an aperture includes a plurality of concentric surface indicia in the base connector to permit a selective formation of an appropriately dimensioned aperture for interconnection with a duct of the air delivery system.

Claim 13

The invention of claim 10 wherein the surface indicia are indented circular patterns molded in the base connector surface.

Claim 14

The invention of claim 9 further including a non-fiberglass sheet sandwiched between at least a pair of glass fiber and plastic binder laminae to assist in sealing the plenum chamber.

Claim 15

The invention of claim 12 wherein the non-fiberglass sheet is formed of paper.

Claim 16

The invention of claim 12 wherein the non-fiberglass sheet is formed of metal.

Claim 17

The invention of claim 12 wherein the metal sheet is a thin sheet of aluminum.

Claim 18

The invention of claim 9 wherein the relative ratio of the thickness of the plenum chamber member wall adjacent the faceplate to the thickness of the base connector is approximately 1 to 6.

Claim 19

The invention of claim 9 wherein the relative ratio of the density of the plenum chamber member wall adjacent the faceplate to the density of the base connector is approximately 4 to 1.

Claim 20

The invention of claim 9 wherein the density of the plenum chamber member wall adjacent the faceplate is approximately twelve pounds per cubic foot.

Claim 21

The invention of claim 9 wherein the laminae comprises approximately 15 percent phenolic binder and 85 percent fibrous glass.

Claim 22

The invention of claim 9 wherein the wall and base connector interior surfaces include carbon black.

Claim 23

The invention of claim 9 having a noise criteria, NC, characteristic value less than an equivalent two foot by two foot metal diffuser assembly in the range of 16 to 46 for a ten inch inlet duct having inlet velocities from 400 feet per minute with a velocity pressure of 0.01 inch of water at NC=16 to 1200 feet per minute with a velocity pressure of 0.09 inches of water at NC=46 based on a room absorption of 8DB, RE 10 -12 watts.

Claim 24

A diffuser assembly for connection to an air delivery system with ducts comprising; a plenum chamber member including a base connector and a wall extending from the base connector to define the plenum chamber cavity, the wall and base connector integrally molded from compressed laminae of approximately 15 percent phenolic binder and 85 percent fibrous glass, the plenum chamber member having an interior fibrous textured surface and a comparatively more dense fibrous exterior laminae surface, the laminae of the base connector being compressed to a density of approximately 3.7 pounds per cubic foot and the laminae of a peripheral edge of the wall being compressed to a density of approximately twelve pounds per cubic foot; means for forming an aperture in the base connector for interconnection with a duct of the air delivery system, and a perforated faceplate connected to the plenum chamber member to close at least a portion of the plenum chamber cavity.

Claim 25

A diffuser assembly for connection to an air delivery system with ducts comprising; a plenum chamber member including a base connector and a wall extending from the base connector to define the plenum chamber cavity, the wall and base connector integrally molded from compressed laminae of approximately 15 percent phenolic binder and 85 percent fibrous glass, the plenum chamber member having an interior fibrous textured surface and a comparatively more dense fibrous exterior laminae surface, the laminae of the base connector being compressed to a density of approximately 3.7 pounds per cubic foot and the laminae of a peripheral edge of the wall being compressed to a density of approximately twelve pounds per cubic foot; means for forming an aperture in the base connector for interconnection with a duct of the air delivery system, and a perforated faceplate connected to the plenum chamber member to close at least a portion of the plenum chamber cavity.

Claim 26

The invention of claim 22 wherein the means for forming an aperture includes a plurality of indented concentric configurations to permit the diffuser assembly to be universally adaptable to various duct sizes by removing a selected concentric configuration compatible with the interfacing duct.

Claim 27

The invention of claim 22 wherein carbon black is mixed with the uncured plastic binder on the interior surface before curing to provide fibrous glass members extending freely from the interior surface.

Claim 28

The invention of claim 24 wherein an intermediate sheet of non-curable material is positioned between at least two layers of fiberglass and uncured phenolic binders.