ANTIMICROBIAL, INJECTION MOLDED AIR REGISTER FOR USE IN AN AIR DISTRIBUTION SYSTEM

Abstract

An antimicrobial, injection molded air register for use in an air distribution system to direct airflow from ductwork into a passenger cabin of a vehicle or into an enclosed space within a residential structure is provided. The air register includes a perforated cover configured to cover an outlet end of the ductwork and a plurality of injection molded components supported by the cover to direct air flow into the passenger cabin. Each of the components includes a surface layer in fluid communication with the airflow and is made of a molded material which absorbs airborne liquid droplets containing infectious, disease-causing pathogens moving with the airflow. The molded material includes antimicrobial agents disbursed throughout each of the surface layers to reduce the number of pathogens contained within droplets absorbed by the surface layers.

Claims

1. An antimicrobial, injection molded air register for use in an air distribution system to direct airflow from ductwork into a passenger cabin of a vehicle, the air register comprising: a perforated cover configured to cover an outlet end of the ductwork; and a plurality of injection molded components supported by the cover to direct air flow into the passenger cabin wherein each of the components includes a surface layer in fluid communication with the airflow and is made of a molded material which absorbs airborne liquid droplets containing infectious, disease-causing pathogens moving with the airflow and wherein the molded material includes antimicrobial agents disbursed throughout each of the surface layers to reduce the number of pathogens contained within droplets absorbed by the surface layers.

2. The air register as claimed in claim 1, wherein the components comprise an assembly of adjustable louvers or vanes configured to distribute the airflow into desired directions into the passenger cabin.

3. The air register as claimed in claim 1, further comprising a damper to control the volume of airflow into the passenger cabin wherein the damper includes a droplet-absorbing surface layer having antimicrobial properties.

4. The air register as claimed in claim 1, wherein the air distribution system comprises an HVAC system which conditions the air provided to the passenger cabin.

5. The air register as claimed in claim 1, wherein the molded material is a hydrophilic thermoplastic composition.

6. The air register as claimed in claim 1, wherein the antimicrobial agents include antiviral agents.

7. An antimicrobial, injection molded air register for use in an air distribution system to direct air flow from ductwork into an enclosed space within a residential structure, the air register comprising: a perforated cover configured to cover an outlet end of the ductwork; and a plurality of injection molded components supported by the cover to direct air flow into the passenger cabin wherein each of the components includes a surface layer in fluid communication with the airflow and is made of a molded material which absorbs airborne liquid droplets containing infectious, disease-causing pathogens moving with the airflow and wherein the molded material includes antimicrobial agents disbursed throughout each of the surface layers to reduce the number of droplet-containing pathogens absorbed by the surface layers.

8. The air register as claimed in claim 7, wherein the components comprise an assembly of adjustable louvers or vanes configured to distribute the airflow into desired directions into the enclosed space.

9. The air register as claimed in claim 7, further comprising a damper to control the volume of airflow into the enclosed space wherein the damper includes a droplet-absorbing surface layer having antimicrobial properties.

10. The air register as claimed in claim 7, wherein the air distribution system comprises an HVAC system which conditions the air provided to the enclosed space.

11. The air register as claimed in claim 7, wherein the molded material is a hydrophilic thermoplastic composition.

12. The air register as claimed in claim 7, wherein the antimicrobial agents include antiviral agents.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0041] FIG. 1 is a front perspective environmental view, partially broken away, of a prior art front dashboard and console within an automotive vehicle HVAC system;

[0042] FIG. 2 is a side perspective environmental view, partially broken away, of a prior art passenger cabin of an autonomous vehicle;

[0043] FIG. 3 is a front schematic view of a prior art air register which has been modified for use in a vehicle HVAC system;

[0044] FIG. 4 is a side schematic view of a prior art mechanism for controlling the volume of airflow in the passenger cabin via the air register of FIG. 3 and which has been modified;

[0045] FIG. 5 is a side, schematic view, partially broken away and in cross section, of a prior art air vent damper apparatus which has been modified and with its damper door shown in a closed, down position;

[0046] FIG. 6 is a view similar to the view of FIG. 5 with the door in an intermediate position;

[0047] FIG. 7 is a view similar to the views of FIGS. 5 and 6 with the door in a fully open position;

[0048] FIG. 8 is a top plan view, partially broken away and in cross-section, of a prior art air duct with turning vanes which has been modified; and

[0049] FIG. 9 is an exploded view, partially broken away and in cross-section, of a prior art air duct which has been modified.

DETAILED DESCRIPTION

[0050] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

[0051] An antimicrobial, injection molded air register, generally indicated at 16 and 16′ in FIGS. 3-4 and 5-7, respectively, for use in an air distribution system such as an HVAC system is used to direct airflow from ductwork, generally indicated at 17 and 17′ in FIGS. 8 and 9, respectively, into a passenger cabin of a vehicle or into an enclosed space within a residential structure. Each air register 16 or 16′ includes a perforated cover 19 or 19′, respectively, configured to cover an outlet end 21 or 21′ of the ductwork 17 or 17′, respectively, and a plurality of injection molded components such as adjustable louvers or vanes 18 or 18′ configured to distribute the airflow into desired directions into the passenger cabin or enclosed space. The louvers or vanes 18 or 18′ are supported by the cover 19 or 19′, respectively, to direct air flow into the passenger cabin.

[0052] Each of the components 18 or 18′ includes one or more surface layers 20 or 20′, respectively, in fluid communication with the airflow and is made of a molded material which absorbs airborne liquid droplets 15 (exaggerated in size in FIG. 8) containing infectious, disease-causing pathogens moving with the airflow. The molded material includes antimicrobial agents disbursed throughout each of the surface layers 20 or 20′ to reduce the number of pathogens contained within the droplets 15 absorbed by the surface layers 20 or 20′.

[0053] The molded material is preferably generally of the type disclosed in U.S. Published Patent Application No. 2019/0352446 and can be characterized as a hydrophilic thermoplastic composition having antimicrobial agents such as antiviral agents.

[0054] The air register 16 or 16′ may further include a damper 24 or 24′ respectively, to control the volume of airflow into the passenger cabin. The damper 24 or 24′ may also include one or more droplet-absorbing surface layers 26 or 26′, respectively, having antimicrobial properties. The air register 16′ may also include an injection molded air register inlet 28′ having an air passageway for communicating air flow towards the cover 19′ as indicted by arrows 29′. The air register inlet 28′ also includes a droplet absorbing, inner surface layer 30′ having antimicrobial properties.

[0055] The air ducts 17 and 17′ are antimicrobial, injection molded air ducts for use in the air distribution system. The air duct 17 or 17′ includes a hollow, injection molded housing, generally indicated at 32 and 32′, respectively, having an air passageway for communicating airflow (as indicated by arrows 34 and 34′) therethrough. The housing 32 or 32′ includes an inner layer 36 or 36′, respectively, of molded material which at least partially defines the passageway and which absorbs airborne liquid droplets 15 (exaggerated in size in FIG. 8) containing infectious, disease-causing pathogens moving with the airflow. The molded material includes antimicrobial agents disbursed throughout the layer 36 or 36′ to reduce the number of pathogens contained within droplets 15 absorbed by the layer 36 or 36′. The housing 32 or 32′ also includes an outer layer 38 or 38′, respectively, made of a molded material compatible with the molded material of the inner layer 36 or 36′.

[0056] As with the layers 20, 20′, 26, 26′ and 30′ of the air registers 16 and 16′ of FIGS. 3-4, and 5-7, respectively, the molded material of the layers 36 and 36′ of the air ducts 17 and 17′, respectively, is generally of the type disclosed in U.S. Published Patent Application No. 2019/0352446. Again, the molded material can be characterized as a hydrophilic thermoplastic composition having antimicrobial agents such as antiviral agents.

[0057] The air duct 17 or 17′ may further comprise a mechanism such as a damper generally of the type shown in FIG. 4 at reference number 24 to control airflow within the air passageway. The mechanism is disposed within the air passageway to adjust the volume of airflow to the passenger cabin or enclosed space. The mechanism may include one or more droplet-absorbing surface layers such as the layers 26 having antimicrobial properties.

[0058] The air duct 17 or 17′ may further comprise one or more turning vanes 40 disposed within the air passageway to minimize turbulence and resistance to airflow within the passageway. The turning vanes 40 may include a droplet-absorbing surface layer having antimicrobial properties as described above or may be completely made of such molded material.

[0059] As shown in FIG. 9, the housing 32′ may include first and second opposed plastic parts 42′ and 44′ secured to one another about their outer perimeters which allows the two parts 42′ and 44′ to come together in a closed configuration in which the parts 42′ and 44′ at least partially define the passageway.

[0060] The parts 42′ and 44′ may be fused or welded together to secure the housing 32′ in the closed configuration.

[0061] Each of the parts 42′ and 44′ may be formed as a unitary molded part having a multilayered wall structure (i.e. the layers 36′ and 38′) obtained by a co-injection process during injection molding or by sandwich injection molding.

[0062] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.