CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority from United States provisional patent application Serial Number US62/147,197 filed on April 14, 2015, entitled REGISTER WITH ELECTRO-MAGNETIC LINEAR ACTUATOR, which is expressly incorporated by reference herein, to the fullest extent permitted by law.

BACKGROUND FIELD

The present invention relates to wireless HVAC control used in home or building automation, security, energy management and assisted living industries. More specifically, the present invention relates to the use of an electro-magnetic linear actuator to open and close an HVAC register.

DESCRIPTION OF RELATED ART

The emergence of the Internet of Things and the Smart Home industries have created an increasing consumer demand for devices within the home, retail, commercial and industrial environments for the controlling, monitoring and reporting of objects to provide a reduction in energy consumption.

One such object is the HVAC register commonly found in a wall, floor or ceiling of a home or business. While the primary function of a device that controls such an object is to actuate the object's physical position or "state" between Closed and Open, information such as object state, environmental conditions and/or control device power source status may also be reported. This reported state and other information may be used by an electronic controller, "gateway" or "hub" within the home or business to make decisions on energy management issues and respond with control commands to various HVAC and other devices accordingly. These decisions are often made in conjunction with HVAC control algorithms or schedules located locally or in remote Cloud or smartphone applications. Manually actuated HVAC registers, in one form or another, have been installed in new building construction or as retro-fitted modifications for many years, primarily by the construction industry. Traditionally, these registers are formed of different materials (metal, plastic, wood, etc), have a range of sizes corresponding to the HVAC ducting they are designed to fit and have a wide variety of aesthetic "grill" designs that allow the consumer to manually actuate an open or closed state.

Automated registers have been developed and deployed in residential, commercial and industrial sites by energy management companies. Installations have been done with AC and DC powered motorized registers, requiring a professional installer to physically modify existing ducting, walls and flooring to accommodate the new register and run long lengths of low or high voltage wire between the registers and one or more system control panels. More recently wireless systems have become more popular, communicating remotely with one or more wireless controllers and making use of battery-powered electric motors, magnets, springs and/or solenoids to actuate the HVAC register.

Historically, the installation challenges presented by these systems have required professional technicians, skilled at modifying HVAC ductwork, knowledgeable about running wires through walls and experienced in deploying and maintaining wireless equipment. The new Smart Home industries have created a Do It Yourself (DIY) retail marketplace, wherein home owners and/or unskilled employees are now faced with installing, operating and maintaining these types of wired or wireless systems and their accompanying devices.

Given the recent changes in the technology and the emergence of DIY customer expectations, all of these types of systems now face the same challenging requirements for wireless HVAC register installation in the home, retail, commercial and industrial market segments. The register devices used to provide energy savings must: be designed to fit easily within the "standard" register duct openings, provide a "quiet" user experience without "ghost" sounds due to actuation late at night, be able to withstand the harsh temperature extremes present within an HVAC duct and be easily installed without professional knowledge or power tools.

Figure 1, 2, 3 and 4 (all PRIOR ART) illustrate wireless HVAC registers that are representative of the majority of registers available.

Figure 1 depicts a Keen Home Smart Vent ^® wireless HVAC register 10 for floor, ceiling and wall installations. The register 10 has a body housing 15 that fits within standard HVAC ducting and supports and contains the component parts of the device. The register 10 is shown in an "open" position, permitting air flow. Mechanical louvers 14 are turned between vertical and horizontal positions, to permit and restrict air flow, by an electric motor and gear assembly 11. Batteries 12 provide a replaceable power source. Manual actuator 13 allows the consumer to open and close the mechanical louvers 14 directly.

Figure 2 and Figure 3 depict an EcoNet Controls Z-Vent ^® Model EV100 wireless HVAC register 20 for floor, ceiling and wall installations. The register 20 has a body housing 24 that fits within standard HVAC ducting and supports and contains the component parts of the device. In Figure 2, register 20 is shown with louvers 21 in a "closed" position, restricting air flow. In Figure 3, register 20 is shown with louvers 21 in an "open" position, permitting air flow. Mechanical louvers 21 are turned between vertical and horizontal positions, to permit and restrict air flow, by an electric motor and gear assembly 23. Batteries 22 provide a replaceable power source.

Figure 4 depicts an Inova Products Inc Activent ^® " wireless HVAC register 40 for floor, ceiling and wall installations. The register 40 has a body housing 44 that fits within standard HVAC ducting 42 and supports and contains the component parts of the device. The register 40 is shown in a "closed" position, restricting air flow. Mechanical louvers 43 are turned between vertical and horizontal positions, to permit and restrict air flow, by an electric motor and gear assembly 45. Batteries 41 provide a replaceable power source.

The primary issues in all of the PRIOR ART depicted in Figures 1, 2, 3 and 4 are the cost, complexity and reliability of the electric motors/gears and rotating louver assemblies. In the harsh and long duration temperature extremes found in residential, commercial or industrial HVAC ducting, measured as high as 80C or more depending on proximity to the furnace, the reliability of any form of lubricated, engaged and moving mechanical solution is prone to mechanical failure. This can be due to a variety of causes, including: simple wear and tear on mechanical parts, loss of internal lubrication in electric motors, loss of lubrication on gears and other components, accelerated heat/cold aging of gear and louver mechanical materials and accelerated heat/cold aging of electric motor internal components. Dust carried by forced air systems and varying humidity further increase the harshness of this operating environment.

A secondary, yet commercially significant issue, is the "ghost" noises caused by the rotary action of the electric motor moving the gears and mechanical louvers late at night. This late night disturbance has been reported as a primary reason for customer rejection of older wired systems.

Consequently, there exists a need for a wireless HVAC register that will : provide a "quiet" user experience without "ghost" sounds due to actuation late at night, be able to withstand the harsh temperature extremes present within an HVAC duct and be easily installed without professional knowledge or power tools

SUMMARY

The present invention is directed to this need.

According to one aspect of the present invention, there is provided a register apparatus, comprising: a body having a first plurality of openings; a grill having a second plurality of openings, the grill being able to move relative to the body between an open position in which the first plurality of openings and the second plurality of openings are aligned, whereby air flow therethrough is permitted, and a closed position in which the first plurality of openings and the second plurality of openings are not aligned, whereby air flow therethrough is restricted; and an electro-magnetic linear actuator, being able to urge the grill to move relative to the body between the open position and the closed position.

The grill may slide within the body between the open position and the closed position. The body has a socket and the grill may have a cavity that loosely circumscribes the socket throughout the transit of the grill between the first position and the second position.

The actuator may include a magnetic circuit, having a first portion of the magnetic circuit retained within the socket and a second portion of the magnetic circuit mounted within the cavity.

In this regard, the second portion may include at least one magnet, and the first portion may include at least one other magnet opposite the at least one magnet and at least one coil between the at least one other magnet and the at least one magnet. Furthermore, at least one of the first portion and the second portion may include a shunt.

Alternatively, the first portion may includes at least one magnet and at least one other magnet opposite the at least one magnet, and the second portion may include at least one coil between the at least one magnet and the at least one other magnet. Furthermore, the first portion may include at least one shunt.

In any case, the may include a housing configured for releasable retention within the socket, and the first portion of the magnetic circuit may be housed within the housing. In some embodiments, at least one of the second portion and the grill passes through the housing.

At least one of the grill and the housing may have a design feature to direct air flow through the register.

The actuator may include a radio to receive a command signal to urge the grill to move relative to the body between the open position and the closed position or to transmit a report signal to report whether the grill is in either the open position or the closed position.

Further aspects and advantages of the present invention will become apparent upon considering the following drawings, description, and claims.

DESCRIPTION

The invention will be more fully illustrated by the following detailed description of non- limiting specific embodiments in conjunction with the accompanying drawing figures. In the figures, similar elements and/or features may have the same reference label. Further, various elements of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar elements. If only the first reference label is identified in a particular passage of the detailed description, then that passage describes any one of the similar elements having the same first reference label irrespective of the second reference label.

BRIEF DESCRIPTION OF THE DRA WINGS

In the accompanying drawings, which illustrate exemplary prior art and exemplary embodiments of the present invention:

Figure 1 (PRIOR ART) is a top view of a Keen Home "Smart Vent" wireless HVAC register.

Figure 2 (PRIOR ART) is a top view of an EcoNet Controls Z-Vent Model EV100 wireless HVAC register in a "closed" position.

Figure 3 (PRIOR ART) is a top view of an EcoNet Controls Z-Vent Model EV100 wireless HVAC register in an "open" position.

Figure 4 (PRIOR ART) is a top view of an Inova Products Inc "Activent" wireless HVAC register.

Figure 5 is a top perspective view of a wireless HVAC register, according to a first embodiment of aspects of the present invention, shown in an open position.

Figure 6 is a bottom perspective view of a wireless HVAC register, according to the first embodiment, shown in an open position.

Figure 7 is a top perspective view of the wireless HVAC register main body, according to the first embodiment.

Figure 8 is a bottom perspective view of the wireless HVAC register main body, according to the first embodiment.

Figure 9 is a top lengthwise cross-sectioned perspective view of the wireless HVAC register main body, according to the first embodiment.

Figure 10 is a front lengthwise cross-sectioned side view of the wireless HVAC register main body, according to the first embodiment. Figure 11 is a top perspective view of the wireless HVAC register grill, according to the first embodiment.

Figure 12 is a bottom perspective view of the wireless HVAC grill, according to the first embodiment.

Figure 13 is a top lengthwise cross-sectioned perspective view of the wireless HVAC register grill, according to the first embodiment.

Figure 14 is a front lengthwise cross-sectioned side view of the wireless HVAC register grill, according to the first embodiment.

Figure 15 is a top perspective view of the wireless HVAC register module, according to the first embodiment.

Figure 16 is a top perspective view of the wireless HVAC module internal components, according to the first embodiment.

Figure 17a is a top lengthwise cross-sectioned perspective view of a wireless HVAC register, according to the first embodiment, shown in an open position.

Figure 17b is a top lengthwise cross-sectioned perspective view of a wireless HVAC register, according to the first embodiment, showing the linear actuator in an open position.

Figure 18a is a top lengthwise cross-sectioned perspective view of a wireless HVAC register, according to the first embodiment, shown in a closed position.

Figure 18b is a top lengthwise cross-sectioned perspective view of a wireless HVAC register, according to the first embodiment, showing the linear actuator in a closed position.

Figure 19 is a top perspective view of a wireless HVAC register, according to a second embodiment of aspects of the present invention, shown in an open position.

Figure 20 is a bottom perspective view of a wireless HVAC register, according to the second embodiment, shown in an open position.

Figure 21 is a top perspective view of the wireless HVAC register main body, according to the second embodiment. Figure 22 is a bottom perspective view of the wireless HVAC register main body, according to the second embodiment.

Figure 23 is a top lengthwise cross-sectioned perspective view of the wireless HVAC register main body, according to the second embodiment.

Figure 24 is a front lengthwise cross-sectioned side view of the wireless HVAC register main body, according to the second embodiment.

Figure 25 is a top perspective view of the wireless HVAC register grill, according to the second embodiment.

Figure 26 is a bottom perspective view of the wireless HVAC grill, according to the second embodiment.

Figure 27 is a top lengthwise cross-sectioned perspective view of the wireless HVAC register grill, according to the second embodiment.

Figure 28 is a front lengthwise cross-sectioned side view of the wireless HVAC register grill, according to the second embodiment.

Figure 29 is a top perspective view of the wireless HVAC register module, according to the second embodiment.

Figure 30 is a bottom perspective view of the wireless HVAC register module, according to the second embodiment.

Figure 31 is a top perspective view of the wireless HVAC module internal components, according to the second embodiment.

Figure 32a is a top lengthwise cross-sectioned perspective view of a wireless HVAC register, according to the second embodiment, shown in an open position.

Figure 32b is a top lengthwise cross-sectioned perspective view of a wireless HVAC register, according to the second embodiment, showing the linear actuator in an open position.

Figure 33a is a top lengthwise cross-sectioned perspective view of a wireless HVAC register, according to the second embodiment, shown in a closed position. Figure 33b is a top lengthwise cross-sectioned perspective view of a wireless HVAC register, according to the second embodiment, showing the linear actuator in a closed position.

Figure 34 is an example of a simplistic implementation of an electro-magnetic linear actuator.

Figure 35 is a top perspective view of the coil assembly of a practical implementation of an electro-magnetic linear actuator, according to the second embodiment.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The structure and operation of the invention will now be illustrated by explanation of specific, non-limiting, exemplary embodiments shown in the drawing figures and described in greater detail herein.

Dimensional or directional terms such as "front", "back, "top", "bottom", "lateral" and "transverse" in this Detailed Description are used merely to assist the reader in understanding the detailed embodiments and are not intended to limit the construction or operation of the embodiments described herein, nor the orientation or connection of the embodiments to the environment or to other structures.

Overview

According to one aspect of the invention, there is provided an HVAC register with an electromagnetic linear actuator. The register has: a physical supporting frame or register main body formed and sized to fit within an HVAC duct aperture; a register grill which when moved in a linear fashion will open or close the register to permit or restrict air flow; a module for a power source, radio, electronic circuitry and electro-magnetic linear actuator which can be attached to and be located within the register body; a power source for the radio, electronic circuitry and electromagnetic linear actuator; a radio which can be used to receive command signals to open and close the register and send report signals on the register "state" as well as other information; electronic circuitry which can be used to support the radio, provide power to the electro-magnetic linear actuator, facilitate register "state" sensing, manage the power source and sense other relevant information; a means-to-detect the "state" of the register; and an electro-magnetic linear actuator.

The register main body can be made of plastic or other suitable materials with a variety of finishes and colours. The register main body design can be such to accommodate a wide range of standard and non-standard commercial HVAC duct apertures. The register main body design can be modified to accommodate for a range of module design variants or other design elements required by its functions and features. The register main body can be installed in the HVAC duct aperture without the use of any tools, except for a ceiling or wall mounting, in which case the pre-existing screws and holes may be used to secure it in place. The installation of the register main body requires no additional modification to any of the floor, wall, ceiling or HVAC ducting.

The register grill can be made of plastic or other suitable materials with a variety of finishes and colours. The register grill design can be modified to accommodate for a range of main body and module design variants or other design elements required by its functions and features. The register grill can contain components of the electro-magnetic linear actuator.

The module can comprise a means to secure itself within the register main body using screws, snaps, clips or any other fastener or means adequate to ensure proper product operation and prevent product damage or failure. The module can contain the power source, radio, electronic circuitry and electro-magnetic linear actuator either completely or partially within its physical envelope. The module can contain or provide physical assistance to part or all of the means-to- detect the register "state".

The power source can comprise an energy storage device using a primary cell battery of alkaline or any other technology or chemistry type. The power source can include the ability, by Power Management Integrated Circuits (PMIC's), passive electronic circuitry or any other means, to provide for product safety and to manage the discharging and other functions of the energy storage device. The radio can have the firmware and electronic circuitry necessary to support and implement the IEEE 802.15.4 ZigBee HA Profile wireless communication standard, or any other form of appropriate communication standard or protocol. The radio can contain an antenna internal or external to the housing to facilitate communication with the wireless system's network.

The electronic circuitry can have the firmware and hardware circuitry necessary to support and implement: the radio and any supporting functions required by it; the means-to-detect the register "state" and any supporting functions required by it; power source management by Power Management Integrated Circuits (PMIC's), passive electronic circuitry or any other means; the sensing of other relevant information such as environmental conditions and power source capacity; and powering the electro-magnetic linear actuator.

The means-to-detect the "state" of the register can include a mechanical element such as a piece of bent metal made from spring steel or phosphor bronze, or any other material being physically displaced by the opening or closing of the register grill, that through physical contact with the register grill, makes contact with and creates a measureable change in electronic circuitry. This measureable change can be detected by the hardware circuitry and/or firmware to produce a discernible Open or Closed "state".

The means-to-detect the "state" of the register can further include sensing the physical displacement of the register grill by: magnetic elements and sensors, optical sensing, Hall Effect sensing of the magnets within the linear actuator, or inductive or capacitive sensing making use of the wound coil of the linear actuator or other means. Additionally, the air flow through the register grill itself and the pressure in the HVAC ducting could be measured by pressure, flow or turbulence sensors to determine the "state" of the register.

The electro-magnetic linear actuator can have a design of the magnetic and electronic components necessary to make use of Lorentz's Law. Lorentz's Law is an expression of the force F acting on a particle of electric charge q with instantaneous velocity v, due to an external electric field E and magnetic field B (where holding denotes a vector), and is defined by the equation: F = q [ E + ( v x B) ]

The resulting direction of the force acting on the particle is determined by the cross product of the vectors representing the magnetic field and the particle's velocity, and is often referred to as the "right hand rule". Making practical use of this "first principles" force will yield effective transformation of energy to movement possible. To do so, and not suffer excessive loss due to friction, requires the design of an electro-magnetic linear actuator using minimal components and, in the embodiments below, only one moving part. An actuator of such minimalistic design will also be cost effective and resilient to the environmental effects of temperature extremes within an HVAC duct system.

Referring to Figure 34 there is shown a simple example of an electro-magnetic linear actuator 340.

When electric wire assembly 341 is placed in the magnetic field 345 that exists between magnet pair 342 and electric current 343 flows in wire assembly 341 as shown, a force 344 acts on wire assembly 341 at right angles to both the direction of magnetic field 345 and the direction of current flow 343, in accordance with the "right hand rule". The force experienced by wire assembly 341 is proportional to the number of independent current-carrying strands within wire assembly 341.

For a practical implementation of Lorentz's Law, referring to Figure 35, the electro-magnetic linear actuator 350 can have two pairs of magnets 351, with alternating and oppositely directed N and S poles, joined by ferrous shunts 352. Ferrous shunts 352 "complete" the magnetic circuit, containing the flux path to a known medium and strengthening the effective magnetic field between magnet pairs 351. Further, the electro-magnetic linear actuator can have a non-ferrous carrier 353 supporting and containing a multi-strand wound coil 354. Carrier 353 can be mobile and when coil 354 is energized it will experience force 355, in a direction dependent on the direction of current flow. Those skilled in the art will recognize that the linear actuator shown in Figure 35 is but one example of a linear actuator that falls within the spirit of the present invention. Those skilled in the art will recognize other suitable arrangements and configurations of magnets and coils, shunts, carriers and in general linear actuator components within the teaching of the present invention.

Unlike alternative solutions, which have exposed motors, gears, levers, solenoids, and/or springs to provide actuation to the register grill, permitting and restricting air flow, the approach taught herein provides a linear actuator with no exposed moving parts, save for the register grill itself. In this manner, the mechanical reliability of the register is fundamentally improved, not only for ideal environment operation but also when exposed to temperature extremes or dirty/dusty environments, like those found within HVAC ducting.

Making use of first principles science like Lorentz's Law, through the implementation of a highly-efficient electro-magnetic linear actuator, provides a cost-effective, reliable and

environmentally robust means to actuate an HVAC register. Unlike prior art examples which require electric motors, gears, louvers, levers, solenoids, magnets and/or springs, the solutions taught herein have only one moving part, require no lubrication and experience a minimal amount of friction during operation. This approach will also provide a quiet means to actuate the HVAC register, having no late night "ghost" noises due to rotating components.

First Embodiment

Referring to Figure 5, there is shown a top perspective view of a first embodiment of a register with an electro-magnetic linear actuator 50 that can be installed in the place of a standard mechanical register. The register 50 as shown in the embodiment is based on a 3"xl0" North American HVAC duct aperture size, but could be based on any duct size or other international standard or could be non-standard. While the register 50 as shown in the embodiment is symmetric with respect to aperture patterns and module location, for the purposes of this Detailed Description, we will use the terms "left" and "right" as viewed in Figure 5. The register 50 can include a register main body 51 and a module 52, as well as a physical control 53 by which the user can manually open and close the register. As shown in the illustrated embodiment, the register 50 facilitates the same physical operation as a standard mechanical register, opening and closing to permit and restrict air flow.

Referring to Figure 6, there is shown a bottom perspective view of the first embodiment of the register with an electro-magnetic linear actuator 50 that can be installed in the place of a standard mechanical register. The register 50 can include a register grill 61 that, by moving in a linear fashion along the long axis of the register, can open and close the register, permitting and restricting air flow.

Referring to Figure 7 and Figure 8, there are shown top and bottom perspective views of the first embodiment of the register main body 51. The main body 51 can include a design 71 of multiple openings to modify the direction and increase the laminar quality of air flow, socket 72 to permit register module 52 to be mounted in main body 51 and an opening 73 for physical control 53.

Referring to Figure 9 and Figure 10, there are shown top perspective and front lengthwise cross-sectioned views of the first embodiment of the register main body 51.

Referring to Figure 11 and Figure 12, there are shown top and bottom perspective views of the first embodiment of the register grill 61. The grill 61 can include an alternating design 111 of multiple openings to allow for the open and closing of register 50. The grill 61 can include a cavity 112 designed to fit with main body 51, loosely circumscribing the socket 72 and, when mounted, the register module 52, so as to be free to slide between open and closed positions, including as urged by the linear actuator. Within cavity 112 can be located magnets 113, which comprise part of the electro-magnetic linear actuator.

Referring to Figure 13 and Figure 14, there are shown top perspective and front lengthwise cross-sectioned views of the first embodiment of the register grill 61. In these views magnets 113 can be more clearly seen as well as ferrous shunt 132, connecting magnets 113 and forming a magnetic circuit. The magnets 113 could be made from any commercial NdFeB, Grade N42

Neodymium material. The ferrous shunt 132 could be made from stamped sheet metal or stainless steel with a relative permeability of 100 or more as compared to vacuum. Grill 61 can also include a design feature 131 to allow for directing of air flow 141 away from cavity 112 and toward alternating design 111 and hence through the register 50.

Referring to Figure 15, there is shown a top perspective view of the first embodiment of the register module 52. Register module housing 151 and internal components 160 are shown as "transparent" to give an indication of the mounting locations for the internal components 160. The overall dimensions of module 52, as shown in the embodiment, might be: 1" x 2" x 1.5", for example. It should be appreciated by anyone skilled in the art, that the dimensions and design of housing 52 may vary significantly depending upon the size and structure of register 50 that it is being used.

Referring to Figure 16, there is shown a top perspective view of the first embodiment of the register module internal components 160. The internal components 160 can include: electronic circuitry 161, power source 162, ferrous shunt 163, magnets 164, and printed circuit coil 165. In this embodiment, the electronic circuitry 161 includes a Printed Circuit Board (PCB) on which is contained the radio, internal antenna and electro-magnetic linear actuator powering circuitry. The exemplary radio could be a Silicon Labs EM357 Integrated Circuit. The exemplary antenna could be a Johanson Technology 2450AT18A100 2.4GHz chip antenna. Adjacent to, and electrically and mechanically connected to electronic circuitry 161, is the power source 162. The power source 162 could be Panasonic AAA primary alkaline cell batteries. The size and dimensions of electronic circuitry 161 and the location of the electronic components on its PCB may both vary greatly depending upon the size and structure of module 52. In this embodiment ferrous shunt 163, magnets 164 and printed circuit coil 165 form the upper half of the electro-magnetic linear actuator. The magnets 164 could be made from any commercial Nd FeB, Grade N42 Neodymium material. The ferrous shunt 163 could be made from stamped sheet metal steel or any other material with a relative permeability of 100 or more as compared to vacuum. These components interact with magnets 113 and ferrous shunt 132 on grill 61 to form the complete electro-magnetic linear actuator. Typical materials that can be used to manufacture the depicted embodiment of register 50 are: polycarbonate plastic with a matte texture for the main body 51, grill 61 and module housing 151. The components of electronic circuitry 161 in the embodiment are readily available from third- party companies in the electronics industry. The housing main body 51, grill 61 and module housing 151 in the embodiment can be formed by an injection plastic molding process; however, other manufacturing techniques can be used as would be known to one skilled in the art.

Referring to Figure 17a, there is shown a top lengthwise cross-sectioned perspective view of the first embodiment of the register 50 in an open position. As can be seen, alternating design 111 of register grill 61 is in alignment with alternating design 71 of main body 51, not restricting air flow. In this first embodiment, the mobile component of the electro-magnetic linear actuator 170 are magnets 113, attached to moving grill 61, rather than printed circuit coil 165. When printed circuit coil 165 is energized and allows current to flow, the force generated by the electro-magnetic linear actuator 170 acts on magnets 113, moving grill 61 into an open position.

Referring to Figure 17b, there is shown a top lengthwise cross-sectioned perspective view of the first embodiment of the register 50 in an open position, zoomed-in to give a better view of the linear actuator 170. The linear actuator 170 comprises: ferrous shunt 163, magnets 164, printed circuit coil 165, magnets 113 and ferrous shunt 132. The dimensions of magnets 164, as shown in the embodiment, might be ¼" x ¼" x 2". The dimensions of ferrous shunt 163, as shown in the embodiment, might be 1mm x 1.5" x 2". The construction of printed circuit coil 165, as shown in the embodiment, might be of dimensions 2mm x 1.5" x 2" and may contain 6 or more layers of circuit board tracing forming a continuous coil, presenting 100 or more effective turns to the magnetic field between magnets 164 and 113. The dimensions of magnets 113, as shown in the embodiment, might be ½" x ¼" x 2". The dimensions of ferrous shunt 132, as shown in the embodiment, might be lmm x 2" x 2". The printed circuit coil 165 can be energized with a current of 1 ampere (A) or more, the effectiveness of this energization is determined by the supplied voltage and ohmic properties of the contained circuit board traces. The magnet field created in the air gap between magnets 164 and 113, as part of the magnetic circuit created by ferrous shunts 163 and 132, can be 0.5 Teslas (T) or more. This described construct is intended to deliver in excess of 3 Newtons (N) of force to move the attached register grill 61 between open and closed positions.

Referring to Figure 18a, there is shown a top lengthwise cross-sectioned perspective view of the first embodiment of the register 50 in a closed position. As can be seen, alternating design 111 of register grill 61 is not in alignment with alternating design 71 of main body 51, restricting air flow. When printed circuit coil 165 is oppositely energized and allows current to flow in the opposite direction, the force generated by the electro-magnetic linear actuator 170 acts instead on magnets 113, moving grill 61 into a closed position.

Referring to Figure 18b, there is shown a top lengthwise cross-sectioned perspective view of the first embodiment of the register 50 in a closed position, zoomed-in to give a better view of the linear actuator 170.

Second Embodiment

The second embodiment is similar in ways to the first embodiment; however, one difference lies in the implementation of the electro-magnetic linear actuator. For the first embodiment, magnetic elements of the actuator are combined with the moving register grill and in the second embodiment the wound coil element of the actuator is combined with the moving register grill. These differences are described more clearly and in full detail in what follows below.

Referring to Figure 19, there is shown a top perspective view of a second embodiment of a register with an electro-magnetic linear actuator 190 that can be installed in the place of a standard mechanical register. The register 190 as shown in the embodiment is based on a 3"xl0" North American HVAC duct aperture size, but could be based on any duct size or other international standard or could be non-standard. While the register 190 as shown in the embodiment is symmetric with respect to aperture patterns and module location, for the purposes of this Detailed Description, we will use the terms "left" and "right" as viewed in Figure 19. The register 190 can include a register main body 191 and a module 192, as well as a physical control 193 by which the user can manually open and close the register. As shown in the illustrated embodiment, the register 190 facilitates the same physical operation as a standard mechanical register, opening and closing to permit and restrict air flow.

Referring to Figure 20, there is shown a bottom perspective view of the second embodiment of a register with an electro-magnetic linear actuator 190 that can be installed in the place of a standard mechanical register. The register 190 can include a register grill 201 that, by moving in a linear fashion along the long axis of the register, can open and close the register, permitting and restricting air flow.

Referring to Figure 21 and Figure 22, there are shown top and bottom perspective views of the second embodiment of the register main body 191. The main body 191 can include a design 211 of multiple openings to modify the direction and increase the laminar quality of air flow, a socket 212 to permit register module 192 to be mounted in main body 191 and an opening 213 for physical control 193.

Referring to Figure 23 and Figure 24, there are shown top perspective and front lengthwise cross-sectioned views of the second embodiment of the register main body 191.

Referring to Figure 25 and Figure 26, there are shown top and bottom perspective views of the second embodiment of the register grill 201. The grill 201 can include an alternating design 251 of multiple openings to allow for the open and closing of register 190. The grill 201 can include a cavity 252 designed to fit with main body 191, loosely circumscribing the socket 212 and, when mounted, the register module 192 so as to be free to slide between open and closed positions, including as urged by the linear actuator. Attached to grill 201 and within cavity 252 can be located a wound coil 253, which comprises part of the electro-magnetic linear actuator.

Referring to Figure 27 and Figure 28, there are shown top perspective and front lengthwise cross-sectioned views of the second embodiment of the register grill 201. In these views wound coil 253 can be more clearly seen. Wound coil 253 can be comprised of a non-ferrous carrier 271, attached to grill 201 and a multi-strand wound coil of wire 272. Non-ferrous carrier 271 can be made from polycarbonate plastic with a matte texture. Wound coil 272 can be made from 28 AWG insulated copper wire or another material of similar ohmic characteristics.

Referring to Figure 29 and Figure 30, there is shown top and bottom perspective views of the second embodiment of the register module 192. The overall dimensions of the housing 291 of module 192, as shown in the embodiment, might be: 1" x 2" x 2", for example. It should be appreciated by anyone skilled in the art, that the dimensions and design of housing 291 may vary significantly depending upon the size and structure of register 190 that it is being used. Housing 291 can also include apertures 292, located on either side of housing 291, to allow wound coil 253 to move with grill 201. Wound coil 253 and grill 201 are attached and mounted within housing 291 at time of manufacture, with the whole assembly then being mounted within register 190.

Alternatively, housing 291 can include a design feature such that it may be opened, the assembly of grill 201 and wound coil 253 inserted, and the housing 291 reclosed. Housing 291 can also include a design feature 293 to allow for directing of air flow away, and toward alternating design 251 and hence through the register 190.

Referring to Figure 31, there is shown a top perspective view of the second embodiment of the register module internal components 310. The internal components 310 can include: electronic circuitry 311, power source 312, ferrous shunt 313, magnets 314, magnets 315 and ferrous shunt 316. In this embodiment, the electronic circuitry 311 includes a Printed Circuit Board (PCB) on which is contained the radio, internal antenna and electro-magnetic linear actuator powering circuitry. The exemplary radio could be a Silicon Labs EM357 Integrated Circuit. The exemplary antenna could be a Johanson Technology 2450AT18A100 2.4GHz chip antenna. Adjacent to, and electrically and mechanically connected to electronic circuitry 311, is the power source 312. The power source 312 could be Panasonic AAA primary alkaline cell batteries. The size and dimensions of electronic circuitry 311 and the location of the electronic components on its PCB may both vary greatly depending upon the size and structure of module 192. In this embodiment ferrous shunt 313, magnets 314, magnets 315 and ferrous shunt 316 form the upper and lower half of the electro- magnetic linear actuator. The magnets 314 and magnets 315 could be made from any commercial Nd FeB, Grade N42 Neodymium material. The ferrous shunt 313 and ferrous shunt 316 could be made from stamped sheet metal or any other material with a relative permeability of 100 or more as compared to vacuum. These components interact with wound coil 253 on grill 201 to form the complete electro-magnetic linear actuator.

Those skilled in the art will appreciate that when the register main body 191, the grill 201 and the module housing 291 are assembled, and thus the grill 201 is slidably constrained within the apertures 292 of the module housing 291, the magnets 314 and 315 will lie on opposite sides of the wound coil 253.

Typical materials that can be used to manufacture the depicted embodiment of register 190 include: polycarbonate plastic with a matte texture for the main body 191, grill 201 and module housing 291. The components of electronic circuitry 311 in the embodiment are readily available from third-party companies in the electronics industry. The housing main body 191, grill 201 and module housing 291 in the embodiment can be formed by an injection plastic molding process; however, other manufacturing techniques can be used as would be known to one skilled in the art.

Referring to Figure 32a, there is shown a top lengthwise cross-sectioned perspective view of the second embodiment of the register 190 in an open position. As can be seen, alternating design 251 of register grill 201 is in alignment with alternating design 211 of main body 191, not restricting air flow. In this second embodiment, the mobile component of the electro-magnetic linear actuator 270 is wound coil 253 attached to moving grill 201. When wound coil 253 is energized and allows current to flow, the force generated by the electro-magnetic linear actuator 270 acts on wound coil 253, moving grill 201 into an open position.

Referring to Figure 32b, there is shown a top lengthwise cross-sectioned perspective view of the second embodiment of the register 190 in an open position, zoomed-in to give a better view of the linear actuator 270. The linear actuator 270 comprises: ferrous shunt 313, magnets 314, multi- strand wound coil of wire 272, non-ferrous carrier 271, magnets 315 and ferrous shunt 316. The dimensions of magnets 314 and 315, as shown in the embodiment, might be ¼" x ¼" x 2". The dimensions of ferrous shunt 313 and ferrous shunt 316, as shown in the embodiment, might be lmm x 2" x 2". The dimensions of non-ferrous carrier 271, as shown in the embodiment, might be 3/8' x 2" x 3". The construction of multi-strand wound coil of wire 272, as shown in the embodiment, might be of dimensions ¼" x 2.5" x 2" and may use 26 AWG or smaller gauge wire wound to form a continuous coil, presenting 150 or more effective turns to the magnetic field between magnets 314 and 315. The multi-strand wound coil of wire 272 can be energized with a current of 1 ampere (A) or more, the effectiveness of this energization is determined by the supplied voltage and ohmic properties of the wire used. The magnet field created in the air gap between magnets 314 and 315, as part of the magnetic circuit created by ferrous shunts 313 and 316, can be 0.5 Teslas (T) or more. This described construct is intended to deliver in excess of 3 Newtons (N) of force to move the attached register grill 201 between open and closed positions.

Referring to Figure 33a, there is shown a top lengthwise cross-sectioned perspective view of the second embodiment of the register 190 in a closed position. As can be seen, alternating design 251 of register grill 201 is not in alignment with alternating design 211 of main body 191, restricting air flow. When wound coil 253 is oppositely energized and allows current to flow in the opposite direction, the force generated by the electro-magnetic linear actuator 270 acts on wound coil 253, moving grill 201 into a closed position.

Referring to Figure 33b, there is shown a top lengthwise cross-sectioned perspective view of the second embodiment of the register 50 in a closed position, zoomed-in to give a better view of the linear actuator 270.

(c) Description Summary

Thus, it will be seen from the foregoing embodiments and examples that there has been described a way to provide an HVAC register with an electro-magnetic linear actuator.

While specific embodiments of the invention have been described and illustrated, such embodiments should be considered illustrative of the invention only and not as limiting the invention as construed in accordance with the accompanying claims. In particular, all quantities described are exemplary, and those skilled in the art might well expect a wide range of values surrounding those described to provide similarly beneficial results.

It will be understood by those skilled in the art that various changes, modifications and substitutions can be made to the foregoing embodiments without departing from the principle and scope of the invention expressed in the claims made herein.

For example, the number and type of magnets or the structure and number of turns in the printed circuit or wound coil could be greatly varied to produce the same effect. Alternatively, the same effect can be achieved by altering the "stack up" of the magnets and ferrous shunts, or by not using any ferrous shunts at all.

For example, the axis of transit of a grill with respect to the main body need not be the long axis.

While the invention has been described as having particular application for HVAC systems in buildings, those skilled in the art will recognize it has wider application.