HVAC Zoning System Having Distributed Intelligence and Method of Manufacture

Abstract

The present application discloses a method of converting a single zone HVAC system to a multi-zoned HVAC system. More specifically, the present application discloses coupling at least one interface module to at least one controller of a heating unit, cooling unit, and blower assembly. Further, at least one thermostat may be positioned within each desired zone of a multi-zoned structure. The user may then position at least one register on at least one terminus of a duct within each zone. Thereafter, each thermostat within each zone is associated or linked via a communication channel or network with at least one register within the same zone, thereby forming at least one thermostat/register regime within each zone of a structure. The interface module may then be associated with the various thermostat/register regimes. The user may the input at least one of a maximum temperature and minimum set temperature for each zone via at least one of the interface module, a thermostat within each zone, and a register within the zone. Once operating, the thermostat with each zone will measure the temperature within that zone and provide the measured temperature to the associated register. In response, the register can restrict of permit the flow of air to the zone by opening and closing the register based on the temperature measured by thermostat within that zone.

What is claimed is: 
     
         1 . A system for controlling a forced air HVAC system, comprising:
 at least one interface module in communication with at least one of a heating unit, cooling unit, and blower assembly of the HVAC system;   at least one thermostat positioned within in a zone within a structure, the thermostat having at least one temperature sensor therein and at least one user-interface device formed thereon, the thermostat is communication with the interface module; and   at least one register coupled to one or more ducts of the HVAC system within the zone, the register in communication with the interface unit, the register configured to selectively permit and restrict the flow of air to the zone from at least one of the heating unit, cooling unit, and blower assembly of the HVAC system based on data from at least one of the interface module, the register, and thermostat.   
     
     
         2 . The system of  claim 1  wherein the interface module includes at least one device selected from the group consisting of processors, memory devices, sensors, detectors, user interface devices, display devices, computer network communication devices, and communication devices. 
     
     
         3 . The system of  claim 2  wherein the interface module is in wireless communication with at least one computer network. 
     
     
         4 . The system of  claim 1  wherein the interface module comprises a computer device. 
     
     
         5 . The system of  claim 1  wherein the interface module includes at least one pressure sensor configured to measure the flow pressure of air flowing through the HVAC system. 
     
     
         6 . The system of  claim 1  wherein the thermostat is configured to communicate with at least one of the interface module and the register wirelessly. 
     
     
         7 . The system of  claim 1  wherein the thermostat is configured to communicate with at least one of the interface module and the register via at least one conduit. 
     
     
         8 . The system of  claim 1  wherein the register includes at least one user interface device thereon. 
     
     
         9 . The system of  claim 1  wherein the register is configured to communicate with at least one of the interface module and the thermostat wirelessly. 
     
     
         10 . The system of  claim 1  wherein the register is configured to communicate with at least one of the interface module and the thermostat via at least one conduit. 
     
     
         11 . The system of  claim 1  wherein the register includes at least one pressure sensor thereon, the pressure sensor configured to measure the flow of air through the register. 
     
     
         12 . The system of  claim 11  wherein a first register is in communication with at least a second register, the first register configured to calculate a back pressure of the HVAC system based on flow information receive from at least one of the first register and the second register. 
     
     
         13 . The system of  claim 1  wherein the register includes at least one temperature sensor thereon. 
     
     
         14 . The system of  claim 1  wherein the register includes at least one actuator thereon, the actuator coupled to at least one flow regulator configured to selectively permit and restrict the flow of air through the register. 
     
     
         15 . The system of  claim 14  wherein the flow regulator comprises at least one brush body configured to selectively engage a body of the register to restrict the flow of air through the register and selectively disengage the body of the register to controllably permit the flow of air through the register. 
     
     
         16 . The system of  claim 1  further comprising at least one HVAC system computer network formed by at least one processor positioned within the interface module, register, and thermostat, the HVAC system network forming a distributed computing network. 
     
     
         17 . The system of  claim 16  wherein the HVAC system computer network is in communication with an externally accessible computer network. 
     
     
         18 . The system of  claim 16  further comprising at least one repeater module in communication with at least one of the HVAC system computer network, the interface module, the register, and the thermostat, the repeater module configured to receive and repeat at least one signal transmitted through the HVAC system computer network. 
     
     
         19 . The system of  claim 16  further comprising at least one temperature sensor contained within the repeater module, the temperature sensor configured to measure at least one temperature within a structure. 
     
     
         20 . The system of  claim 16  further wherein the repeater module is in communication with at least one of an AC power source and a DC power source, the repeater module configured to provide a redundant temperature reading within a structure. 
     
     
         21 . The system of  claim 16  wherein the repeater module include at least one user interface configured to permit a user to user set a minimum temperature and maximum temperature with the structure. 
     
     
         22 . The system of  claim 16  wherein at least one of the interface module, thermostat, register, and repeater module includes at least one auxiliary component selected from the group consisting of carbon monoxide sensors, smoke detectors, radon detectors, occupancy sensors, emergency light devices, cameras, motion detectors, and security devices. 
     
     
         23 . A method of converting a single zone HVAC system to a multi-zoned HVAC system, comprising:
 coupling at least one interface module to at least one controller of a heating unit, cooling unit, and blower assembly;   positioning at least one thermostat in each zone of a multi-zoned structure;   positioning at least one register on at least one terminus of a duct within each zone;   associating at least one thermostat within each zone with at least one register within the same zone, thereby forming at least one thermostat/register regime within each zone of a structure;   associating at least one register within each thermostat/register regime with interface module;   inputting at least one of a maximum set target temperature and minimum set target temperature for each zone via at least one of the interface module, a thermostat within each zone, and a register within the zone;   measuring a temperature within a zone using the thermostat of the associated thermostat/register regime to providing temperature data to the register of the associated thermostat/register regime; and   restricting and permitting the flow of air to the zone by opening and closing the register of the associated thermostat/register regime based on the temperature data provided by thermostat within the same zone.   
     
     
         24 . The method of  claim 23  wherein the thermostat and register within each zone communicate wirelessly. 
     
     
         25 . The method of  claim 23  wherein the thermostat and register within each zone communicate via at least one conduit. 
     
     
         26 . The method of  claim 23  wherein the register and interface module communicate wirelessly. 
     
     
         27 . The method of  claim 23  wherein the register and interface module communicate via at least one conduit. 
     
     
         28 . The method of  claim 23  wherein at least one thermostat within each zone is in communication with the interface module. 
     
     
         29 . The method of  claim 28  wherein the thermostat communicates with the interface module wirelessly. 
     
     
         30 . The method of  claim 28  wherein the thermostat communicates with the interface module via at least one conduit. 
     
     
         31 . The method of  claim 23  wherein at least one of the thermostat, register, and interface module communicate via at least one computer network. 
     
     
         32 . The method of  claim 23  wherein:
 a user inputs at least one of a maximum and minimum set temperature for each zone via at least one thermostat within the zone; 
 the set temperatures are transmitted to and stored by at least one register within the same zone; 
 the register restricts or permits the flow of air through the register by comparing the stored set temperatures to the temperatures measured by the thermostat within the same zone. 
 
     
     
         33 . The method of  claim 23  wherein:
 a user inputs at least one of a maximum and minimum set target temperature for each zone via the interface module; 
 the set temperatures are stored by the interface module; 
 at least one thermostat within each zone measures the temperature with that zone and transmits the temperature data to the interface module; 
 the interface module compares the stored set temperatures to the temperature data within each zone; 
 the interface module transmits a register command to at least one register within each zone based on the comparison of the temperature data and set temperature; and 
 the register restricts or permits the flow of air through the register based on the register command. 
 
     
     
         34 . The method of  claim 23  wherein:
 a user inputs at least one of a maximum and minimum set temperature for each zone via at least one register within a zone; 
 the set temperatures are stored by the register; 
 at least one thermostat within each zone measures the temperature with that zone and transmits the temperature data to the register; 
 the register compares the stored set temperatures to the temperature data with each zone; and 
 the register restricts or permits the flow of air through the register based on the comparison of the temperature data to the stored set temperature. 
 
     
     
         35 . The method of  claim 23  further comprising measuring at least one of a flow pressure and back pressure within the HVAC system with at least one sensor within the register and controlling any number of registers in communication with the interface module to optimize flow pressure through the HVAC system 
     
     
         36 . A method of converting a single zone HVAC system to a multi-zoned HVAC system, comprising:
 coupling at least one interface module to at least one controller of a heating unit, cooling unit, and blower assembly;   positioning at least one thermostat in each zone of a multi-zoned structure;   positioning at least one register on at least one terminus of a duct within each zone;   associating the thermostat within each zone with the register within the same zone, thereby forming at least one thermostat/register regime within each zone of a structure;   associating at least one of the thermostat and register with the interface module;   inputting at least one of a maximum temperature and minimum set target temperature for each zone via at least one of the interface module, a thermostat within each zone, and a register within the zone;   measuring a temperature within a zone using at least one of the thermostat and register;   providing the temperature data to the interface module; and   restricting and permitting the flow of air to the zone by opening and closing the register based on at least one command sent by the interface module to the register based on at least one comparison of the temperature data to the stored set temperature.   
     
     
         37 . The method of  claim 36  wherein at least one of the thermostat, register, and interface module communicate via at least one computer network. 
     
     
         38 . The method of  claim 36  wherein at least one of the thermostat, register, and interface module communicate wirelessly. 
     
     
         39 . A system for controlling a forced air HVAC system, comprising:
 at least one interface module in communication with at least one of a heating unit, cooling unit, and blower assembly of the HVAC system;   at least one pressure sensor in communication with the interface module and at least one duct of the HVAC system, the pressure sensor configured to measure a flow pressure within the HVAC system;   at least one thermostat positioned within in a zone within a structure, the thermostat having at least one temperature sensor therein and at least one user-interface device formed thereon;   at least one repeater module having at least one memory device therein, the repeater module in communication with at least one AC power source and at least one DC power source;   at least one register coupled to one or more ducts of the HVAC system within the zone, the register having at least one flow regulator configured to permit and restrict the flow of air through the register therein; and   at least one computer network wirelessly coupling the interface module, thermostat, repeater module, and register, the computer network configured to permit communication between at least one of the interface module, thermostat, repeater module, and register.   
     
     
         40 . The system of  claim 39  further comprising at least one processor located within the thermostat, the processor in communication with the user-interface device of the thermostat and configured to store at least one user-defined maximum and minimum set target temperature for a selected zone therein. 
     
     
         41 . The system of  claim 39  further comprising at least one processor located within the repeater module, the repeater module processor in communication with the interface module and configured to receive and store the maximum and minimum set temperature therein, the repeater module configured to initiate at least one of a heating cycle and cooling cycle of the HVAC system should at least one of the maximum and minimum set temperature be reached. 
     
     
         42 . The system of  claim 39  further comprising at least one temperature sensor positioned within the repeater module. 
     
     
         43 . The system of  claim 39  wherein the repeater module includes at least one device selected from group consisting of power interrupt sensors, carbon monoxide sensors, radon detectors, smoke detectors, emergency lighting systems, supplemental lighting devices, occupancy sensors, nightlights, motion detectors, and cameras. 
     
     
         44 . The system of  claim 39  wherein the register includes at least one actuator coupled to the flow regulator, the actuator configured to selectively move the flow regulator to permit or restrict the flow of air through the register. 
     
     
         45 . The system of  claim 42  further comprising at least one processor in communication with the actuator and computer network, the processor configured to direct the actuator to restrict or permit the flow of air through the register based at least one command from the computer network. 
     
     
         46 . The system of  claim 39  wherein the flow regulator comprises a brush body device configured to selectively engage at least a portion of the body of the register to restrict the flow of air through the register. 
     
     
         47 . The system of  claim 39  wherein the computer network includes at least one control processor. 
     
     
         48 . The system of  claim 45  wherein the network processor comprises a distributed processor formed by processors within one or more interface modules, one or more thermostats, one or more repeater modules, and one or more registers. 
     
     
         49 . A system for controlling a forced water HVAC system, comprising:
 at least one interface module in communication with at least one of a heating unit, cooling unit, and pump of the force water HVAC system;   at least one manifold coupled to the pump, the manifold having multiple valved outlets thereon;   a number of fluid circuits formed with a structure each defining a thermal zone within a structure, the fluid circuit coupled to an in fluid communication with at least one valved outlet;   at least one thermostat positioned within in each thermal zone, the thermostat having at least one temperature sensor therein and at least one user-interface device formed thereon; and   at least one computer network in communication with the interface module, the valved outlets, and the thermostats, wherein at least one thermostat with the thermal zone measures the temperature with the thermal zone and provides the temperature data to the interface module, wherein the valved outlets are in communication with the interface module and configured to selectively permit and restrict the flow of fluid there through based on direction from the interface module.