HVAC Zoning System Having Distributed Intelligence and Method of Manufacture

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.

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.

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.

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.