Diffuser
A diffuser includes a plastics baffle which has an air inlet end, an air outlet end and an outwardly tapering wall extending between the air inlet end and the air outlet end, and which defines a diffusing air chamber. A plurality of circumferentially spaced weld ribs is upstanding from the air outlet end. A plastics grille has a plurality of air outlets and an annular shelf to which the weld ribs of the baffle are ultrasonically welded.
1. A diffuser for attachment to an airflow outlet end of a hair dryer, the diffuser comprising:
a plastics baffle comprising an air inlet end, an air outlet end and an outwardly tapering wall extending between the air inlet end and the air outlet end, and which defines a diffusing air chamber, the air outlet end comprising a plurality of circumferentially spaced weld ribs upstanding therefrom; and
a plastics grille comprising a plurality of air outlets and an annular shelf to which the weld ribs of the baffle are ultrasonically welded.
2. The diffuser of claim 1 , wherein an internal surface of the grille comprises a first connector and the baffle comprises a second connector, wherein a first one of the first and second connectors comprises a male connector and a second one of the first and second connectors comprises a female connector for receiving the male connector.
3. The diffuser of claim 2 , wherein the connectors comprise inter-engaging angular alignment members.
4. The diffuser of claim 1 , comprising a plastics external wall which surrounds the wall of the baffle to define an air channel therebetween.
5. The diffuser of claim 4 , wherein the external wall comprises a plurality of angularly spaced weld ribs which are ultrasonically welded to the air outlet end of the baffle.
6. The diffuser of claim 5 , wherein the ribs of the external wall and the ribs of the baffle are each arranged in a circular pattern, and a diameter of the circular pattern of the ribs of the external wall is substantially the same as a diameter of the circular pattern of the ribs of the baffle.
7. The diffuser of claim 6 , wherein the ribs of the external wall are angularly aligned with the ribs of the baffle.
8. The diffuser of claim 5 , wherein the ribs of the external wall are each upstanding from a respective spacer formed on the internal surface of the external wall for spacing the external wall from the wall of the baffle.
9. The diffuser of claim 8 , wherein the air outlet end of the baffle comprises an angular alignment member which is located between adjacent spacers of the external wall.
10. A method of assembling a diffuser, comprising:
providing a plastics baffle comprising an air inlet end, an air outlet end and an outwardly tapering wall extending between the air inlet end and the air outlet end, and which defines a diffusing air chamber, the air outlet end comprising a plurality of circumferentially spaced weld ribs upstanding therefrom and arranged in a circular pattern;
providing a plastics grille comprising a plurality of air outlets and an annular shelf;
positioning the grille over the air outlet end of the baffle so that the weld ribs engage an internal surface of the shelf; and
ultrasonically welding the grille to the baffle.
11. The method of claim 10 , comprising:
providing a plastics external wall comprising a plurality of circumferentially spaced weld ribs arranged in a circular pattern having a diameter that is the same as a diameter of the circular pattern of the ribs of the baffle;
positioning the baffle within the external wall; and
ultrasonically welding the external wall to the baffle.
12. The method of claim 11 , wherein the external wall is welded to the baffle simultaneously with the welding of the grille to the baffle.