Forced-air zone climate control system for existing residential houses

• US 6,983,889 B2
• Filed: 03/21/2003
• Issued: 01/10/2006
• Est. Priority Date: 03/21/2003
• Status: Active Grant

• Current Assignee: Emme E2MS, LLC
• Original Assignee: Home Comfort Zones Incorporated
• Inventors: Alles, Harold Gene
• Primary Examiner(s): Tapolcai, William E.
• Assistant Examiner(s): Ali, Mohammad M.
• Application Number:
  US10/249,198
• Publication Number:
  US 20040182941A1
• Time in Patent Office: 1,026 Days
• Field of Search: 236/1.B, 236/49.1, 236/49.3, 236/49.4, 236/51, 621/86
• US Class Current: 236/49.1
• CPC Class Codes: F24F 13/10 movable, e.g. dampers
• CPC Class Codes: F24F 2013/087 using inflatable bellows
• CPC Class Codes: F24F 3/0442 with volume control at a constant temperature
• CPC Class Codes: Y10T 137/87249 Multiple inlet with multiple outlet
• CPC Class Codes: Y10T 137/87684 Valve in each inlet
• CPC Class Codes: Y10T 137/87692 With common valve operator
• CPC Class Codes: Y10T 29/49716 Converting

Abstract

A low cost and easy to install zone climate control system for retrofit to an existing forced air HVAC system, that provides independent minute-by-minute, day-by-day, and room-by-room climate control, including easy to use methods for specify temperature schedules and providing local temperature control, and providing detailed energy use information so occupants can make informed cost versus comfort decisions.

Claims

1. A zone climate control system, for installation in an existing forced air HVAC system in a building, comprising:

1) a plurality of airflow control devices adapted for installation inside air vents in rooms of said building;

2) first means for independently controlling each said airflow control device by selectively providing one of pressurized air and vacuum, said first means mounted on a discharge plenum of said HVAC system such that said first means is accessible from an inside of said plenum;

3) second means for connecting each said airflow control device to said first means such that said second means is entirely inside said plenum and said air ducts, and such that said first means controls each said airflow control device through said second means;

4) an air pump that provides pressurized air and vacuum; and

5) a plurality of independently operable air valves, each air valve including,

a) an alpha means for connecting to said pressurized air,

b) a beta means for connecting to said vacuum, and

c) a valve slide having a pressure position adapted to provide a path from said alpha means to said second means, and a vacuum position adapted to provide a path from said beta means to said second means;

6) a delta means for moving one at a time any one of the valve slides to either said pressure position or said vacuum position, the delta means responsive to valve control signals generated by a controlling processor; and

7) an epsilon means for positioning said delta means such that each of the valve slides can be independently set to said pressure position or said vacuum position, said epsilon means responsive to position control signals generated by said controlling processor;

whereby said first means, said second means, and each said airflow control device of said control system are installed by accessing only said plenum and said air vents; and

whereby said air ducts are unmodified in any other way; and

whereby said air ducts remain assembled throughout said installation; and

whereby said installation is simplified; and

whereby various combinations of said valve control signals and said position control signals independently cause either said pressurized air or said vacuum to be connected to each of the plurality of said second means for connecting.

2. A zone climate control system for installation in an existing forced air HYAC system in a building comprising:

1) a plurality of airflow control devices adapted for installation inside air vents in rooms of said building, said airflow control devices controlled and actuated by connections passing entirely through air ducts from said air vents in said rooms to a discharge plenum of said HVAC system;

2) a plurality of battery powered wireless thermometer devices located in a plurality of said rooms, each said wireless thermometer device associated with at least one of said airflow control devices and located such that an air temperature at said wireless thermometer device is affected more by airflow from its associated said air vent than from any other said air vent, said wireless thermometer device transmitting temperature data and unique identification data such that said temperature data can be associated with the corresponding said wireless thermometer device;

3) a first means for receiving said temperature data and said unique identification data from each of said wireless thermometer devices, the means for receiving located proximally to said plenum; and

4) a second means for processing said temperature data and said unique identification data and for generating control commands through said connections passing entirely through said air ducts that control said airflow control devices and for generating control commands that control said HVAC system such that the temperature at each said wireless thermometer device is maintained within a predetermined temperature range, said second means located proximally to said plenum;

whereby said airflow control devices of said control system are installed by accessing only said plenum and said air vents in said rooms, and said air ducts are otherwise unmodified and remain assembled throughout installation; and

whereby said wireless thermometers are installed without wiring between said rooms; and

whereby installation of said control system in said building is simplified and non-obtrusive.

3. The control system of claim 2 wherein the plurality of said wireless thermometer devices each transmits said temperature data and said identification data as digital packets using a same radio frequency, such that a transmission time for each said packet is short compared to a time between transmission of successive said packets, and such that each said wireless thermometer device independently varies the time between transmission of said packets such that each said wireless thermometer device has substantially a same probability of transmitting said packet at a time when no other wireless thermometer device is transmitting said packet, whereby a multitude of wireless thermometer devices can transmit said packets using said same radio frequency, and whereby said first means for receiving receives sufficient said packets free of interference from other said wireless thermometer devices such that said second means for processing is able to maintain the temperature at each said wireless thermometer device within the predetermined temperature range.

4. The control system of claim 2 wherein the plurality of said wireless thermometer devices each has at least one pushbutton for entering commands, and wherein the wireless thermometer devices transmit pushbutton command data, the first means for receiving receives said pushbutton command data, and the second means for processing responds to said pushbutton command data in a predetermined way to alter said predetermined temperature range.

5. The control system of claim 4 wherein the plurality of said wireless thermometer devices each transmits said temperature data and said identification data and said pushbutton command data as digital packets using a same radio frequency, such that a transmission time for each said packet is short compared to a time between transmission of successive said packets, and such that each said wireless thermometer device independently varies the time between transmission of said packets such that each said wireless thermometer device has substantially a same probability of transmitting said packet at a time when no other wireless thermometer device is transmitting said packet, whereby a multitude of wireless thermometer devices can transmit said packets using said same radio frequency, and whereby said first means for receiving receives, sufficient said packets free of interference from other said wireless thermometer devices such that said second means for processing is able to maintain the temperature at each said wireless thermometer device within the predetermined temperature range.

6. The control system of claim 2 further comprising:

1) a means for specifying a plurality of temperature schedules, each said temperature schedule spanning a 24-hour period and comprising one or more said predetermined temperature ranges spanning corresponding periods within said 24-hour period;

2) a means for assigning a said temperature schedule to each said wireless thermometer device; and

3) a means for transferring said temperature schedules and said assignments to said second means;

whereby the temperature at each wireless thermometer device is controlled according to respective said temperature schedules.

7. The control system of claim 6 further comprising a means for assigning different said temperature schedules to each day of a 7-day cycle for each said wireless temperature device.

8. The control system of claim 6 further comprising a means for assigning to at least one said wireless thermometer device at least one of said temperature schedules for at least one predetermined future date.

9. The control system of claim 6 further including a means for specifying a plurality of comfort climates each comprising a lower predetermined temperature and a higher predetermined temperature, and a means for using the comfort climates to provide said predetermined temperature ranges, whereby changes made to said comfort climates also change all respective said predetermined temperature ranges of said temperature schedules.

10. A zone climate control system for an HVAC system comprising:

1) a plurality of airflow control devices adapted for installation inside air vents in rooms of said building, said airflow control devices controlled and actuated by connections passing entirely through air ducts from said air vents in said rooms to a discharge plenum of said HVAC system;

2) a plurality of battery powered wireless thermometer devices located in a plurality of said rooms, each said wireless thermometer device associated with at least one of said airflow control devices and located such that a temperature at said wireless thermometer device is affected more by airflow from the associated air vent than by airflow from any other air vent, each said wireless thermometer device having at least one pushbutton for making at least one pushbutton command, said wireless thermometer devices transmitting temperature data, pushbutton command data, and unique identification data such that said temperature data and said pushbutton command data can be associated with said wireless thermometer device;

3) a first means for receiving said temperature data, said pushbutton command data, and said identification data from each of said wireless thermometer devices, said first means located proximally to said plenum;

4) a second means for specifying a plurality of temperature schedules and associating one of said temperature schedules with each said wireless thermometer device for each day of a 7-day cycle; and

5) a third means for processing said temperature data, said pushbutton command data, and said identification data received by the first means, and for processing said temperature schedules from said second means, and for generating control commands that control said airflow control devices, and for generating control commands that control said HVAC system such that the temperature at each said wireless thermometer device is maintained according to respective said temperature schedules;

whereby the temperature at each said wireless thermometer device is controlled according to the respective assignment of one of a plurality of said temperature schedules for each day of said 7-day cycle.

11. The control system of claim 10 further including a means for associating at least one of a plurality of predetermined pushbutton command functions with each of said wireless thermometer devices, whereby said pushbutton commands from each said wireless thermometer device can be adapted for functions appropriate for an occupant in a proximity of each said wireless thermometer device.

12. The control system of claim 11 wherein one of said predetermined pushbutton command functions temporarily changes a currently associated temperature schedule such that a current predetermined temperature range is changed by a predetermined amount and for a predetermined time after which said temperature range returns to a value that is current at an end of said predetermined time, whereby said occupant can temporarily change the temperature in the proximity of said wireless thermometer by a single press of said pushbutton on said wireless thermometer device.

13. The control system of claim 11 wherein one of said predetermined pushbutton command functions changes an association of at least one said temperature schedule with at least one said wireless thermometer device for an indefinite time, whereby said occupant can permanently change at least one said temperature schedule by a single press of said pushbutton on said wireless thermometer device.

14. The control system of claim 10 further including a pressure sensor for measuring air pressure in said plenum, and said third means further includes a means for relating said measured plenum pressure to total airflow through said plenum and in turn said air ducts.

15. The control system of claim 14 wherein said second means for specifying further includes a means for specifying one of a plurality of levels of airflow noise during the 24-hour span of said temperature schedules, and said third means for processing further includes a means for predetermining the maximum plenum pressure allowed for each airflow noise level, and a means for controlling said plenum pressure using said airflow control devices such that said maximum plenum pressure is not exceeded, whereby the noise level is controlled.

16. The control system of claim 14 wherein said third means for processing further includes a means for storing said plenum pressure and for storing a setting of each said airflow control device for each cycle of said HVAC system and for periodically processing stored data to determine the relative airflow for each said air vent for each said cycle of said HVAC system, whereby relative energy used for each said air vent is determined, and whereby energy used to maintain said temperature schedules at each said wireless thermometer device is determined.

17. The control system of claim 16 wherein said second means for specifying further includes a means for receiving relative energy use data for each said wireless thermometer device and displaying said energy use data in a way informative to said occupant.

18. The control system of claim 17 wherein said second means for specifying further includes a means for using said relative energy use data to estimate a corresponding change in energy use for changes in said temperature schedules, whereby said occupant is informed of an approximate change in future energy use resulting from current said changes in said temperature schedules.

19. The control system of claim 16 further including a wireless thermometer device adapted for measuring an outside temperature, and said third means for processing further includes a means for storing the outside temperature and periodically processing stored outside temperature data and said stored data to determine an approximate thermal resistance from a proximity of each said wireless thermometer device to the outside, and said second means for specifying further includes a means for receiving thermal resistance data for each said wireless thermometer device and displaying said thermal resistance data in a way informative to said occupant, whereby thermal paths with smaller thermal resistance are identified for potential improvement.

20. The control system of claim 10 wherein said third means for processing further includes a means for generating maintenance messages, and said second means for specifying further includes a means for displaying said maintenance messages, and said system further includes a means for alerting said occupant responsive to requests from said third means, whereby said occupant uses said second means to receive said maintenance messages.

21. The control system of claim 20 wherein said wireless thermometer devices includes means for reporting a low battery, said first means for receiving further includes a means for receiving the low battery report and said third means for processing further includes a means for receiving said low battery report from said first means and for generating a maintenance message reporting said low battery report from said wireless thermometer, whereby said occupant is alerted to replace the battery in said wireless thermometer device.

22. The control system of claim 20 wherein said first means for receiving further includes a means for measuring a received signal strength of each said wireless thermometer devices and said third means for processing further comprises a means for receiving and comparing said received signal strengths to predetermined acceptable strengths, and for generating a maintenance message reporting signal strengths less than said acceptable strengths, whereby said occupant is alerted to weak signal strengths.

23. The control system of claim 10 wherein said third means for processing further includes processing to use only a blower of said HVAC system to selectively circulate air to equalize the temperatures comprising:

a) processing to identify at least two of said rooms that have respective said temperatures that differ by a predetermined amount;

b) controlling said airflow control devices such that airflow is enabled only to the identified said rooms; and

c) controlling said blower to cause circulation of air;

whereby the air from said identified said rooms is selectively mixed to equalize respective said temperatures.

24. A zone climate control system for an HVAC system comprising:

1) a plurality of airflow control devices adapted for installation inside air vents in rooms of said building, said airflow control devices controlled and actuated by connections passing entirely through air ducts from said air vents in said rooms to a discharge plenum of said HVAC system;

2) a first means for airflow bypass from said plenum to an air return of said HVAC system, said fourth means comprising an air duct and a bypass airflow control;

3) a second means for sensing an air pressure in said plenum;

4) a third means for sensing an air temperature in said plenum;

5) a plurality of battery powered wireless thermometer devices located in a plurality of said rooms, each said wireless thermometer device associated with at least one of said airflow control devices and located such that a temperature at said wireless thermometer device is affected more by the airflow from associated said air vents in said room than by airflow from any other air vent, each said wireless thermometer device having at least one pushbutton for making at least one pushbutton command, said wireless thermometer devices transmitting temperature data, pushbutton command data, and unique identification data such that said temperature data and said pushbutton command data can be associated with said wireless thermometer device;

6) a fourth means for receiving said temperature data, said pushbutton command data, and said identification data from each of said wireless thermometer devices, said fourth means located proximally to said plenum;

7) a fifth means for specifying a plurality of temperature schedules and associating one of said temperature schedules with each said wireless thermometer device for each day of a 7-day cycle; and

8) a sixth means for processing the plenum pressure from said second means, the plenum temperature from said third means, said temperature data, said pushbutton command data, said identification data received by the fourth means, and the temperature schedules from said fifth means, and for generating control commands that control said airflow control devices in said air vents and said first means, and for generating control commands that control said HVAC system, such that the temperature at each said wireless thermometer device is maintained according to respective said temperature schedules;

whereby the temperature at each said wireless thermometer device, is controlled according to the respective assignment of one of a plurality of said temperature schedules for each day of said 7-day cycle.

25. The control system of claim 24 wherein said sixth means for processing further includes:

a) a means for predicting said plenum pressure for any combination of settings of said airflow control devices and setting of said bypass airflow control;

b) a means for comparing the predicted plenum pressure to a predetermined maximum plenum pressure; and

c) a means for determining a combination of the airflow control device settings and the bypass airflow control setting such that the predicted plenum pressure is less than the maximum plenum pressure, and such that said airflow control device settings maintain the temperature at each said wireless thermometer device within the temperature ranges of said respective temperature schedules;

whereby said HVAC system is operated such that said plenum pressure is less than said maximum plenum pressure.

26. The control system of claim 25 wherein said airflow bypass provides sufficient bypass airflow such that said plenum pressure is less than said maximum plenum pressure when more than approximately 80% of said air vents are obstructed by said airflow control devices, whereby a small number of rooms can be conditioned at one time.

27. The control system of claim 26 wherein said sixth means for processing further includes processing to monitoring said plenum temperature while an HVAC system component is conditioning the air, and for comparing said plenum temperature to predetermined temperature limits, and for turning off said HVAC system component when said plenum temperature is outside said predetermined temperature limits, whereby said HVAC system can condition a small number of rooms at one time.

28. The control system of claim 25 wherein said sixth means for processing further includes processing such that if only one of said rooms needs conditioning, and if conditioning only said one room would cause said plenum pressure to exceed said maximum plenum pressure, then selecting for conditioning at least one additional room from among those rooms closest to their respective temperature range such that said plenum pressure will be less than said maximum plenum pressure, whereby said HVAC system is activated if only a single room needs conditioning.

29. The control system of claim 24 wherein said sixth means for processing further includes processing to use only a blower of said HVAC system to selectively circulate air to equalize the temperatures, comprising:

a) a means for predicting said plenum pressure for any combination of settings of said airflow control devices and setting of said bypass airflow control;

b) a means for comparing the predicted plenum pressure to a predetermined maximum plenum pressure;

c) processing to identify at least two of said rooms that have respective temperatures that differ by a predetermined amount;

d) if said predicted plenum pressure is greater than said maximum plenum pressure, processing to select one at a time additional said rooms with respective temperatures between the respective temperatures of the identified said rooms, until said predicted plenum pressure is less than said maximum plenum pressure;

e) controlling said airflow control devices such that airflow is enabled only to said identified said rooms and only the additionally selected said rooms; and

g) controlling said blower to cause circulation of air;

whereby selective temperatures are equalized.

30. The control system of claim 24 wherein said sixth means for processing further includes processing to use only a blower of said HVAC system to selectively circulate air to equalize temperatures, comprising:

a) a means for predicting said plenum pressure for any combination of settings of said airflow control devices and setting of said bypass airflow control;

b) a means for comparing the predicted plenum pressure to a predetermined maximum plenum pressure;

c) processing to identify at least two of said rooms that have respective temperatures that differ by a predetermined amount;

d) if said predicted plenum pressure is greater than said maximum plenum pressure, enabling said bypass airflow control;

e) if said predicted plenum pressure is greater than said maximum plenum pressure, processing to select one at a time additional said rooms with respective temperatures between the respective temperatures of the identified said rooms, until said predicted plenum pressure is less than said maximum plenum pressure;

f) controlling said airflow control devices such that airflow is enabled only to said identified said rooms and the additionally selected said rooms; and

g) controlling said blower to cause circulation of air;

whereby selective temperatures are equalized.

31. A zone climate control system for retrofitting to an existing forced-air system, the existing forced-air system including a blower, at least one of a heater and a cooler, a conditioned air plenum, and a plurality of air ducts, the zone climate control system comprising:

a plurality of bladders, each disposed within a respective one of the air ducts;

a plurality of air tubes, each coupled to a respective one of the bladders and extending through a respective one of the air ducts into the conditioned air plenum;

a plurality of valves each coupled to a respective one of the air tubes;

an air pump coupled to the plurality of valves to provide pressure and vacuum; and

a computer-controlled valve actuator coupled to the plurality of valves for selectively coupling each air tube to a respective one of the pressure and the vacuum to accordingly inflate or deflate a respective one of the bladders and thereby block or pass air from the conditioned air plenum through the respective air duct; and

a plurality of thermometers each disposed in proximity to a respective one of the bladders, and in communication with the computer-controlled valve actuator.

32. The zone climate control system of claim 31 wherein:

the plurality of thermometers are wirelessly coupled to the computer-controlled valve actuator.

33. A zone climate control system for retrofitting to an existing forced-air system, the existing forced-air system including a blower, at least one of a heater and a cooler, a conditioned air plenum, and a plurality of air ducts, the zone climate control system comprising:

a plurality of bladders, each disposed within a respective one of the air ducts;

a plurality of air tubes, each coupled to a respective one of the bladders and extending through a respective one of the air ducts into the conditioned air plenum;

a plurality of valves each coupled to a respective one of the air tubes;

an air pump coupled to the plurality of valves to provide pressure and vacuum; and

a computer-controlled valve actuator coupled to the plurality of valves for selectively coupling each air tube to a respective one of the pressure and the vacuum to accordingly inflate or deflate a respective one of the bladders and thereby block or pass air from the conditioned air plenum through the respective air duct; and

a bypass air duct coupling the conditioned air plenum to an intake side of the blower.

34. The zone climate control system of claim 33 further comprising:

a bladder and an air tube disposed within the bypass air duct and coupled to one of the valves.

35. A forced-air system comprising:

a blower;

at least one of a heater and a cooler coupled to the blower;

a conditioned air plenum coupled to the at least one of a heater and a cooler;

a plurality of air ducts coupled to the conditioned air plenum;

a plurality of air vents each coupled to a respective one of the air ducts;

at least one bladder, each disposed within a respective one of the air ducts;

at least one air tube, each coupled to a respective bladder and extending from the respective bladder through the respective air duct into the conditioned air plenum; and

an air pump coupled to the air tube to inflate and deflate the bladder;

the at least one bladder comprises a plurality of bladders;

the at least one air tube comprises a plurality of air tubes;

a plurality of valves, each valve coupled between the air pump and a respective air tube;

a plurality of valves, each valve coupled between the air pump and a respective air tube;

a valve manifold coupled to the air pump and containing the plurality of valves; and

a plurality of wireless thermometers each located substantially near a respective air vent; and

an actuator for individually operating the valves to control inflation of the bladders and thereby determine whether each respective air vent emits conditioned air from the conditioned air plenum.

36. A forced-air system comprising:

a blower;

at least one of a heater and a cooler coupled to the blower;

a conditioned air plenum coupled to the at least one of a heater and a cooler;

a plurality of air ducts coupled to the conditioned air plenum;

a plurality of air vents each coupled to a respective one of the air ducts;

at least one bladder, each disposed within a respective one of the air ducts;

at least one air tube, each coupled to a respective bladder and extending from the respective bladder through the respective air duct into the conditioned air plenum; and

an air pump coupled to the air tube to inflate and deflate the bladder;

the at least one bladder comprises a plurality of bladders;

the at least one air tube comprises a plurality of air tubes;

a plurality of valves, each valve coupled between the air pump and a respective air tube; and

a bypass air duct coupling the conditioned air plenum to an intake side of the blower.

37. The forced-air system of claim 36 further comprising:

a bladder and an air tube disposed within the bypass air duct and coupled to one of the valves.