U.S. patent application number 13/098265 was filed with the patent office on 2012-11-01 for blower assembly.
This patent application is currently assigned to TRANE INTERNATIONAL INC.. Invention is credited to Kirk W. Beason, Mark Hudgins, Richard Lee Jameson, Jeffrey L. Stewart.
Application Number | 20120276836 13/098265 |
Document ID | / |
Family ID | 47068242 |
Filed Date | 2012-11-01 |
United States Patent
Application |
20120276836 |
Kind Code |
A1 |
Stewart; Jeffrey L. ; et
al. |
November 1, 2012 |
Blower Assembly
Abstract
An air handling unit has a blower assembly, a first interior
zone, and a second interior zone and the blower assembly physically
separates the first interior zone from the second interior zone. A
method includes providing a cabinet configured to receive a blower
assembly, inserting a blower assembly into the air duct, and
closing a cabinet door of the cabinet, wherein upon closing the
cabinet door, the primary air flow path from a location within the
cabinet downstream of the blower assembly to a location within the
cabinet upstream of the blower assembly is through a blower housing
of the blower assembly. A blower assembly has a blower housing
comprising at least one air inlet and at least one air outlet and a
blower deck extending from the outlet, wherein the blower deck
comprises at least one substantially flat component having a
substantially orthogonal wall extending from the flat
component.
Inventors: |
Stewart; Jeffrey L.;
(Whitehouse, TX) ; Hudgins; Mark; (Whitehouse,
TX) ; Jameson; Richard Lee; (Tyler, TX) ;
Beason; Kirk W.; (Tyler, TX) |
Assignee: |
TRANE INTERNATIONAL INC.
Piscataway
NJ
|
Family ID: |
47068242 |
Appl. No.: |
13/098265 |
Filed: |
April 29, 2011 |
Current U.S.
Class: |
454/251 |
Current CPC
Class: |
F24F 1/0067 20190201;
F24F 13/20 20130101; F24F 1/0022 20130101; F24F 1/0063 20190201;
F24F 13/222 20130101; F24F 1/0007 20130101 |
Class at
Publication: |
454/251 |
International
Class: |
F24F 7/06 20060101
F24F007/06 |
Claims
1. An air handling unit, comprising: a blower assembly; a first
interior zone; and a second interior zone; wherein the blower
assembly physically separates the first interior zone from the
second interior zone.
2. The air handling unit of claim 1, wherein the first interior
zone is associated with an input to a blower housing of the blower
assembly.
3. The air handling unit of claim 2, wherein the second interior
zone is associated with a blower output of the blower housing.
4. The air handling unit of claim 3, wherein a pressure
differential between the first interior zone and the second
interior zone is primarily attributable to a zone boundary between
the first interior zone and the second interior zone provided by a
blower deck of the blower assembly.
5. The air handling unit of claim 4, wherein the blower deck is
formed integrally with the blower housing and wherein the blower
housing houses at least a portion of a motor of the blower assembly
and an impeller of the blower assembly.
6. The air handling unit of claim 4, wherein substantially the
entire zone boundary is formed by components of the blower
assembly.
7. The air handling unit of claim 6, wherein at least one of the
components forming the zone boundary are sloped to manage a flow of
water away from an electrical component of the blower assembly.
8. The air handling unit of claim 1, wherein the blower deck
extends substantially an entire distance from a left interior wall
of a blower cabinet of the air handling unit to an opposite right
interior wall of the blower cabinet.
9. The air handling unit of claim 8, wherein the blower deck
extends from a blower outlet to a rear interior wall of the air
handling unit.
10. The air handling unit of claim 9, wherein the blower deck
extends from the blower outlet to a front panel of the blower
cabinet.
11. A method of creating air pressure zones in an air handling
unit, comprising: providing a cabinet configured to receive a
blower assembly; inserting a blower assembly into the air duct; and
closing a cabinet door of the cabinet; wherein upon closing the
cabinet door, the primary air flow path from a location within the
cabinet downstream of the blower assembly to a location within the
cabinet upstream of the blower assembly is through a blower housing
of the blower assembly.
12. The method of claim 11, further comprising: blocking air flow
around the primary air flow path by spanning a blower deck of the
blower assembly between the interior walls of the cabinet.
13. The method of claim 11, wherein the blower assembly comprises a
blower deck extending between at least two opposing interior walls
of the cabinet.
14. The method of claim 13, further comprising: sliding the blower
deck into integral mounting channels of the at least two opposing
interior walls of the cabinet.
15. The method of claim 14, further comprising: sliding the blower
deck into a third mounting channel of the interior walls of the
cabinet.
16. A blower assembly for an air handling unit of an HVAC system,
the blower assembly comprising: a blower housing comprising at
least one air inlet and at least one air outlet; and a blower deck
extending from the outlet, wherein the blower deck comprises at
least one substantially flat component having a substantially
orthogonal wall extending from the flat component.
17. The blower assembly of claim 16, wherein the wall is located
along an edge of the flat component.
18. The blower assembly of claim 17, wherein a structural web
extends between the wall and the flat component.
19. The blower assembly of claim 17, wherein a structural web
extends between the flat component and the blower housing.
20. The blower assembly of claim 16, wherein the blower assembly
comprises a first shell mated to a second shell and wherein the
first shell comprises a portion of each of the blower housing and
the blower deck and wherein the second shell comprises a portion of
each of the blower housing and the blower deck.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
BACKGROUND
[0004] Heating, ventilation, and air conditioning systems (HVAC
systems) sometimes comprise air handling units comprising blower
assemblies that attach to zone separation decks of the air handling
units.
SUMMARY OF THE DISCLOSURE
[0005] In some embodiments, an air handling unit is provided that
comprises a blower assembly, a first interior zone, and a second
interior zone, wherein the blower assembly physically separates the
first interior zone from the second interior zone.
[0006] In other embodiments, a method of creating air pressure
zones in an air handling unit is provided that comprises providing
a cabinet configured to receive a blower assembly, inserting a
blower assembly into the air duct, and closing a cabinet door of
the cabinet, wherein upon closing the cabinet door, the primary air
flow path from a location within the cabinet downstream of the
blower assembly to a location within the cabinet upstream of the
blower assembly is through a blower housing of the blower
assembly.
[0007] In yet other embodiments, a blower assembly for an air
handling unit of an HVAC system is provided and the blower assembly
comprises a blower housing comprising at least one air inlet and at
least one air outlet and a blower deck extending from the outlet,
wherein the blower deck comprises at least one substantially flat
component having a substantially orthogonal wall extending from the
flat component.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a more complete understanding of the present disclosure
and the advantages thereof, reference is now made to the following
brief description, taken in connection with the accompanying
drawings and detailed description, wherein like reference numerals
represent like parts.
[0009] FIG. 1 is an oblique view of an air handling unit according
to embodiments of the disclosure;
[0010] FIG. 2 is an orthogonal view of the front of the air
handling unit of FIG. 1;
[0011] FIG. 3 is a partially exploded oblique view of the air
handling unit of FIG. 1;
[0012] FIG. 4 is a simplified oblique view of the air handling unit
of FIG. 1 showing a plurality of inner shell components encased
within outer skins;
[0013] FIG. 5 is an oblique left side view of the heat exchanger
cabinet right shell of FIG. 1;
[0014] FIG. 6 is an oblique left side view of the blower cabinet
right shell of FIG. 1;
[0015] FIG. 7 is an oblique view of a blower assembly of FIG. 2
from a front-upper-right viewpoint;
[0016] FIG. 8 is an orthogonal front view of the blower assembly of
FIG. 2;
[0017] FIG. 9 is an orthogonal rear view of the blower assembly of
FIG. 2;
[0018] FIG. 10 is an orthogonal top view of the blower assembly of
FIG. 2;
[0019] FIG. 11 is an orthogonal bottom view of the blower assembly
of FIG. 2;
[0020] FIG. 12 is an orthogonal right side view of the blower
assembly of FIG. 2;
[0021] FIG. 13 is a partial cross-sectional orthogonal right side
view of the blower assembly of FIG. 2;
[0022] FIG. 14 is an oblique partial view of the blower assembly of
FIG. 2 from a rear-upper-right viewpoint; and
[0023] FIG. 15 is an oblique partial exploded view of the blower
assembly of FIG. 2 from a rear-lower-right viewpoint.
DETAILED DESCRIPTION
[0024] Interior walls of some air handling units may be planar in
construction, covered with insulation that may release particulate
matter, and may be configured to carry a plurality of brackets for
carrying removable components of the air handling units. The
removable components of such air handling units may need to be
rearranged to configure the air handling unit for use in a
particular installation configuration with respect to the direction
of gravity. For example, a removable drain pan may need to be
relocated within the air handling unit for use in a particular
installation configuration. Still further, construction of the air
handling units may be time consuming and/or difficult due to a need
to install a variety of brackets and/or support structures to the
interior walls of the air handling units. Further, removal and/or
replacement of the removable components of some current air
handling units may be unnecessarily difficult due to complicated
multi-piece mounting brackets and supports.
[0025] Accordingly, the present disclosure provides, among other
features, an air handling unit (AHU) that comprises interior
cabinet walls shaped and/or otherwise configured to selectively
carry removable components of the AHU with a reduced need for
brackets and supports. The interior cabinet walls of the AHU of the
present disclosure may be further shaped and/or otherwise
configured to reduce or eliminate the need to rearrange components
within the AHU to configure the AHU for a selected installation
orientation relative to the direction of gravity. In some
embodiments, an AHU of the disclosure may comprise interior cabinet
walls that are formed and/or shaped to integrally comprise brackets
and/or other mounting features for carrying removable components.
In some embodiments, an AHU may comprise integral drain pans, the
integral drain pans being suitable for use in different
installation orientations with respect to the direction of
gravity.
[0026] AHUs of some HVAC systems comprise blower assemblies that
attach to zone separation decks installed in the blower cabinet
portion of the AHUs. In some cases, the zone separation decks are
structurally inadequate to prevent significant amounts of
vibration, stress cracks, and/or other mechanical failures due to
the deck carrying heavy blower assemblies. In some cases, the zone
separation decks may be formed as a substantially planar component
having a hole shaped and/or sized to accommodate connection to an
output of the blower assembly. In some cases, the hole in the
planar component is located well within the entrance to the blower
assemblies so that installation and removal of a blower assembly
requires reaching far into the blower cabinet while simultaneously
attempting to align features of the blower assembly with
complementary features of the deck.
[0027] Accordingly, the present disclosure, in some embodiments,
provides systems and methods for providing and/or installing blower
assemblies without the need to carefully manage the position of a
heavy blower assembly while installing it into an AHU. In some
embodiments, the present disclosure provides a blower assembly
comprising an integral blower deck. In some embodiments, the
integral blower deck may easily be received into an AHU by sliding
edges of the integral blower deck into mounting channels of the
AHU. In some embodiments, the mounting channels of the AHU may be
located along the interior walls of the AHU. In some embodiments,
the mounting channels may be integral with the interior walls of
the AHU.
[0028] Referring now to FIGS. 1-3, an AHU 100 according to the
disclosure is shown. In this embodiment, AHU 100 comprises a lower
blower cabinet 102 attached to an upper heat exchanger cabinet 104.
Most generally and for purposes of this discussion, AHU 100 may be
described as comprising a top side 106, a bottom side 108, a front
side 110, a back side 112, a left side 114, and a right side 116.
Such directional descriptions are meant to assist the reader in
understanding the physical orientation of the various components
parts of the AHU 100 but that such directional descriptions shall
not be interpreted as limitations to the possible installation
orientations of an AHU 100. Further, the above-listed directional
descriptions may be shown and/or labeled in the figures by
attachment to various component parts of the AHU 100. Attachment of
directional descriptions at different locations or two different
components of AHU 100 shall not be interpreted as indicating
absolute locations of directional limits of the AHU 100, but
rather, that a plurality of shown and/or labeled directional
descriptions in a single Figure shall provide general directional
orientation to the reader so that directionality may be easily
followed amongst various Figures. Still further, the component
parts and/or assemblies of the AHU 100 may be described below as
generally having top, bottom, front, back, left, and right sides
which should be understood as being consistent in orientation with
the top side 106, bottom side 108, front side 110, back side 112,
left side 114, and right side 116 of the AHU 100.
[0029] Blower cabinet 102 comprises a four-walled fluid duct that
accepts fluid (air) in through an open bottom side of the blower
cabinet 102 and allows exit of fluid through an open top side of
the blower cabinet 102. In this embodiment, the exterior of the
blower cabinet 102 comprises a blower cabinet outer skin 118 and a
blower cabinet panel 120. The blower cabinet panel 120 is removable
from the remainder of the blower cabinet 102 thereby allowing
access to an interior of the blower cabinet 102. Similarly, heat
exchanger cabinet 104 comprises a four-walled fluid duct that
accepts fluid (air) from the blower cabinet 102 and passes the
fluid from an open bottom side of the heat exchanger cabinet 104
and allows exit of the fluid through an open top side of the heat
exchanger cabinet 104. In this embodiment, the exterior of the heat
exchanger cabinet 104 comprises a heat exchanger cabinet outer skin
122 and a heat exchanger cabinet panel 124. The heat exchanger
cabinet panel 124 is removable from the remainder of the heat
exchanger cabinet 104 thereby allowing access to an interior of the
heat exchanger cabinet 104.
[0030] The AHU 100 further comprises a plurality of selectively
removable components. More specifically, the AHU 100 comprises a
heater assembly 126 and may be removably carried within the heat
exchanger cabinet 104. The AHU 100 further comprises a
refrigeration coil assembly 128 that may also be removably carried
within the heat exchanger cabinet 104. In this embodiment, the
heater assembly 126 is configured to be optionally carried within
heat exchanger cabinet 104 nearer the top side 106 of the AHU 100
than the refrigeration coil assembly 128. Similarly, the AHU 100
comprises a blower assembly 130 that may be removably carried
within the blower cabinet 102. The AHU 100 may be considered fully
assembled when the blower assembly 130 is carried within the blower
cabinet 102, each of the refrigeration coil assembly 128 and the
heater assembly 126 are carried within the heat exchanger cabinet
104, and when the blower cabinet panel 120 and heat exchanger
cabinet panel 124 are suitably associated with the blower cabinet
outer skin 118 and the heat exchanger cabinet outer skin 122,
respectively. When the AHU 100 is fully assembled, fluid (air) may
generally follow a path through the AHU 100 along which the fluid
enters through the bottom side 108 of the AHU 100, successively
encounters the blower assembly 130, the refrigeration coil assembly
128, and the heater assembly 126, and thereafter exits the AHU 100
through the top side 106 of the AHU 100.
[0031] In this embodiment, each of the four walls of the blower
cabinet 102 and the heat exchanger cabinet 104 are configured to
have a double-wall construction. More specifically, the heat
exchanger cabinet 104 further comprises a heat exchanger cabinet
right shell 132 and a heat exchanger cabinet left shell 134. In
this embodiment, the heat exchanger cabinet right shell 132 and the
heat exchanger cabinet left shell 134 may be joined to generally
form the interior of the heat exchanger cabinet 104. In order to
form the above-mentioned double-wall construction for the heat
exchanger cabinet 104, the heat exchanger cabinet outer skin 122
generally covers the right side and back side of the heat exchanger
cabinet right shell 132 while also generally covering the left side
and back side of the heat exchanger cabinet left shell 134. Most
generally, the heat exchanger cabinet right shell 132, the heat
exchanger cabinet left shell 134, and the heat exchanger cabinet
outer skin 122 are shaped so that upon their assembly together a
heat exchanger cabinet wall space exists between the heat exchanger
cabinet outer skin 122 and each of the heat exchanger cabinet right
shell 132 and the heat exchanger cabinet left shell 134. The blower
cabinet right shell 136, the blower cabinet left shell 138, and the
blower cabinet outer skin 118 are also shaped so that upon their
assembly together a blower cabinet wall space exists between the
blower cabinet outer skin 118 and each of the blower cabinet right
shell 136 and the blower cabinet left shell 138.
[0032] In some embodiments, one or more of the heat exchanger
cabinet wall space and blower cabinet wall space may be at least
partially filled with an insulating material. More specifically, in
some embodiments, a polyurethane foam may at least partially fill
exchanger cabinet wall space and the lower cabinet wall space. At
least partially filling one or more of the spaces may increase a
structural integrity of the AHU 100, may increase a thermal
resistance of the AHU 100 between the interior of the AHU 100 and
the exterior of the AHU 100, may decrease air leakage from the AHU
100, and may reduce and/or eliminate the introduction of volatile
organic compounds (VOCs) into breathing air attributable to the AHU
100. Such a reduction in VOC emission by the AHU 100 may be
attributable to the lack of and/or reduced use of traditional
fiberglass insulation within the AHU 100 made possible by the
insulative properties provided by the polyurethane foam within the
spaces.
[0033] In some embodiments, each of the blower cabinet outer skin
118 and the heat exchanger cabinet outer skin 122 may be
constructed of metal and/or plastic. Each of the heat exchanger
cabinet right shell 132, the heat exchanger cabinet left shell 134,
blower cabinet right shell 136, and blower cabinet left shell 138
may be constructed of a sheet molding compound (SMC). The SMC may
be chosen for its ability to meet the primary requirements of
equipment and/or safety certification organizations and/or its
relatively rigid cleanable surfaces that are resistant to mold
growth and compatible with the use of antimicrobial cleaners.
Further, the polyurethane foam used to fill the spaces may comprise
refrigerant and/or pentane to enhance the thermal insulating
characteristics of the foam. Of course, in alternative embodiments,
any other suitable material may be used to form the components of
the AHU 100.
[0034] Further, each of the heat exchanger cabinet right shell 132
and the heat exchanger cabinet left shell 134 comprise an interior
side surface 146, an interior rear surface 148, an exterior side
surface, and an exterior rear surface. Similarly, each of the
blower cabinet right shell 136 and the blower cabinet left shell
138 comprise an interior side surface 154, an interior rear surface
156, an exterior side surface, and an exterior rear surface. Most
generally, and with a few exceptions, each of the pairs of interior
side surfaces 146, interior rear surfaces 148, exterior side
surfaces, exterior rear surfaces, interior side surfaces 154,
interior rear surfaces 156, exterior side surfaces, and exterior
rear surfaces are substantially mirror images of each other. More
specifically, the above listed pairs of surfaces are substantially
mirror images of each other about a bisection plane 162 (see FIG.
2) that is generally parallel to both the AHU left side 114 and the
AHU right side 116 and which is substantially equidistant from both
the AHU left side 114 and the AHU right side 116.
[0035] Referring now to FIGS. 4 and 5, simplified views of the AHU
100 are provided. Each of the heat exchanger cabinet right shell
132, the heat exchanger cabinet left shell 134, the blower cabinet
right shell 136, and the blower cabinet left shell 138 comprise
integral features for carrying removable components of the AHU 100.
More specifically, the interior side surfaces 146 and interior rear
surfaces 148 of the heat exchanger cabinet right shell 132 and the
heat exchanger cabinet left shell 134 comprise heater assembly
mounting channels 200 bound above and below by heater assembly
rails 202. The heater assembly rails 202 protrude inwardly from the
remainder of the respective interior side surfaces 146 and interior
rear surfaces 148 so that complementary shaped structures of the
heater assembly 126 may be received within the channels 200 and
retained within the channels 200 by the heater assembly rails 202.
In this embodiment, the heater assembly 126 may be selectively
inserted into the heat exchanger cabinet 104 by aligning the heater
assembly 126 properly with the heater assembly mounting channels
200 and sliding the heater assembly 126 toward the AHU back side
112. Of course, the heater assembly 126 may be selectively removed
from the heat exchanger cabinet 104 by sliding the heater assembly
126 away from the AHU back side 112. Further, one or more of the
interior side surfaces 146 may comprise a heater assembly shelf 204
to slidingly receive a portion of the heater assembly 126 during
insertion of the heater assembly 126 until the heater assembly 126
abuts a shelf back wall 206.
[0036] Still referring to FIGS. 4 and 5, the interior side surfaces
146 of the heat exchanger cabinet right shell 132 and the heat
exchanger cabinet left shell 134 comprise refrigeration coil
assembly mounting channels 208 bound above and below by
refrigeration coil assembly rails 210. The refrigeration coil
assembly rails 210 protrude inwardly from the remainder of the
respective interior side surfaces 146 so that complementary shaped
structures of the refrigeration coil assembly 128 may be received
within the channels 208 and retained within the channels 208 by the
refrigeration coil assembly rails 210. In this embodiment, the
refrigeration coil assembly 128 may be selectively inserted into
the heat exchanger cabinet 104 by aligning the refrigeration coil
assembly 128 properly with the refrigeration coil assembly mounting
channels 208 and sliding the refrigeration coil assembly 128 toward
the AHU back side 112. Of course, the refrigeration coil assembly
128 may be selectively removed from the heat exchanger cabinet 104
by sliding the refrigeration coil assembly 128 away from the AHU
back side 112.
[0037] It will further be appreciated that one or more of the heat
exchanger cabinet right shell 132 and the heat exchanger cabinet
left shell 134 may comprise integrally formed electrical conduit
apertures 212 which form openings between the interior of the heat
exchanger cabinet 104 and the heat exchanger cabinet wall space.
The electrical conduit apertures 212 are formed and/or shaped to
closely conform to the shape of electrical lines and/or electrical
conduit that may be passed through the electrical conduit apertures
212. However, in some embodiments, stabilizer pads 214 may be
integrally formed about the circumference of the electrical conduit
apertures 212 so that the electrical lines and/or electrical
conduit may be more tightly held, isolated from the general
cylindrical surface of the electrical conduit apertures 212, and/or
to reduce friction of insertion of electrical lines and/or
electrical conduit while retaining a tight fit between the
stabilizer pads 214 and the electrical lines and/or electrical
conduit. Further, the stabilizer pads 214 may be configured to
interact with nuts of electrical conduit connectors so that the
stabilizer pads 214 serve to restrict rotational movement of such
nuts. By restricting such rotational movement of nuts, the
stabilizer pads 214 may provide easier assembly and/or disassembly
of the electrical conduit and related connectors to the heat
exchanger cabinet 104. The electrical conduit apertures 212 are not
simply holes formed in the interior side surfaces 146, but rather,
are substantially tubular protrusions extending outward from the
exterior side surfaces.
[0038] It will further be appreciated that one or more of the heat
exchanger cabinet right shell 132 and the heat exchanger cabinet
left shell 134 may comprise drain pan indentions 216. More
specifically, the heat exchanger interior side surfaces 146 may
generally comprise a sloped portion 218 sloped from a bottom side
to the drain pan indentions 216 so that the bottom of the interior
side surfaces 146 protrude further inward and the remainder of the
sloped portion 218. The drain pan indentions 216 may form a
concavity open toward the interior of the heat exchanger cabinet
104. The interior side surfaces 146 further comprises a front
boundary wall 220 with integral drain tubes 222 extending into the
concavity formed by the drain pan indentions 216. In some
embodiments, the AHU 100 may be installed and/or operated in an
installation orientation where the drain pan indention 216 of an
interior side surface 146 is located below the refrigeration coil
assembly 128 and so that fluids may, with the assistance of
gravity, aggregate within the concavity of the drain pan indention
216 and thereafter exit the AHU 100 through the integral drain
tubes 222. More specifically, the sloped portion 218 may direct
fluids falling from the refrigeration coil assembly 128 toward the
concavity formed by a drain pan indention 216. In this manner, the
integrally formed slope portion 218, the drain pan indentions 216,
and the front boundary wall 220 may serve as a condensation drain
pan for the AHU 100 and may prevent the need to install a separate
drain pan and/or to rearrange the configuration of a separate drain
pan based on a chosen installation orientation for the AHU 100.
Further, when in use, a drain pan indention 216 and sloped portion
218 may cooperate with airflow generated by blower assembly 130 to
direct condensation to the integral drain tubes 222.
[0039] It will further be appreciated that one or more of the heat
exchanger cabinet right shell 132 and the heat exchanger cabinet
left shell 134 may comprise integral assembly recesses 224.
Assembly recesses 224 may be located near a lower end of the heat
exchanger cabinet right shell 132 and the heat exchanger cabinet
left shell 134. Assembly recesses 224 may accept mounting hardware
therein for joining the heat exchanger cabinet 104 to the blower
cabinet 102. In this embodiment, the recesses 224 are substantially
shaped as box shaped recesses, however, in alternative embodiments,
the recesses 224 may be shaped any other suitable manner.
Additionally, one or more of the heat exchanger cabinet right shell
132 and the heat exchanger cabinet left shell 134 may comprise
integral fastener retainer protrusions 226. Fastener retainer
protrusions 226 may be used to hold threaded nuts or other
fasteners. Further, in other embodiments, retainer protrusions 226
may themselves be threaded or otherwise configured to selectively
retaining fasteners inserted therein. Still further, the heat
exchanger cabinet right shell 132 and the heat exchanger cabinet
left shell 134 may comprise support bar slots 228 configured to
receive the opposing ends of a selectively removable structural
crossbar.
[0040] Referring now to FIGS. 4 and 6, one or more of the blower
cabinet right shell 136 and the blower cabinet left shell 138 may
comprise blower assembly mounting channels 230 bound above and
below by blower assembly rails 232. The blower assembly rails 232
protrude inwardly from the remainder of the respective interior
side surfaces 154 so that complementary shaped structures of the
blower assembly 130 may be received within the channels 230 and
retained within the channels 230 by the blower assembly rails 232.
In this embodiment, the blower assembly 130 may be selectively
inserted into the blower cabinet 102 by aligning the blower
assembly 130 properly with the blower assembly mounting channels
230 and sliding the blower assembly 130 toward the AHU back side
112. Of course, the blower assembly 130 may be selectively removed
from the blower cabinet 102 by sliding the blower assembly 130 away
from the AHU back side 112.
[0041] It will further be appreciated that one or more of the
blower cabinet right shell 136 and the blower cabinet left shell
138 may comprise filter mounting channels 234 bound above and below
by filter rails 236. The filter rails 236 protrude inwardly from
the remainder of the respective interior side surfaces 154 so that
complementary shaped structures of a filter may be received within
the channels 234 and retained within the channels 234 by the filter
rails 236. In this embodiment, a filter may be selectively inserted
into the blower cabinet 102 by aligning the filter properly with
the filter mounting channels 234 and sliding the filter toward the
AHU back side 112. Of course, the filter may be selectively removed
from the blower cabinet 102 by sliding the filter away from the AHU
back side 112. In some embodiments, the filter mounting channel 234
may be sloped downward from the front to the back of the AHU 100.
Further, in some embodiments, one or more of the filter rails 236
may comprise filter protrusions 238 which may serve to more tightly
hold a filter inserted into the filter mounting channels 234. In
some embodiments, one or more of the blower cabinet right shell 136
and the blower cabinet left shell 138 may comprise fastener
retainer protrusions 226. Still further, one or more of the blower
cabinet right shell 136 and the blower cabinet left shell 138 may
comprise integral assembly recesses 240. Assembly recesses 240 may
be located near an upper end of the blower cabinet right shell 136
and the blower cabinet left shell 138. Assembly recesses 240 may
accept mounting hardware therein for joining the blower cabinet 102
to the heat exchanger cabinet 104. In this embodiment, the recesses
240 are substantially shaped as box shaped recesses, however, in
alternative embodiments, the recesses 240 may be shaped in any
other suitable manner.
[0042] While many of the features of the heat exchanger cabinet
right shell 132, heat exchanger cabinet left shell 134, blower
cabinet right shell 136, and blower cabinet left shell 138 may be
formed integrally to those respective components in a single
molding and/or injection process. However in alternative
embodiments, the various integral features may be provided through
a series of moldings, and/or injections, thermal welding, gluing,
or any other suitable means of assembling a singular structure
comprising the various features as is well known to those skilled
in the art. Further, one or more of the components disclosed herein
as being formed integrally, in some embodiments, may be formed from
multiple components coupled together.
[0043] Referring now to FIGS. 7-13, the blower assembly 130 is
shown in greater detail. FIG. 7 is an oblique view of the blower
assembly 130 from a front-upper-right viewpoint. FIG. 8 is an
orthogonal front view of the blower assembly 130. FIG. 9 is an
orthogonal rear view of the blower assembly 130. FIG. 10 is an
orthogonal top view of the blower assembly 130. FIG. 11 is an
orthogonal bottom view of the blower assembly 130. FIG. 12 is an
orthogonal right side view of the blower assembly 130. FIG. 13 is a
partial cross-sectional orthogonal right side view of the blower
assembly 130. FIG. 14 is an oblique partial view of the blower
assembly 130 from a rear-upper-right viewpoint. FIG. 15 is an
oblique partial exploded view of the blower assembly 130 from a
rear-lower-right viewpoint.
[0044] The blower assembly 130 comprises a motor 300 having a shaft
upon which an impeller 304 is mounted. The motor 300 is attached to
a motor mount 306 that holds the motor 300 in place relative to a
left shell 308 of the blower assembly 130 and a right shell 310 of
the blower assembly 130. In this embodiment, left shell 308 and the
right shell 310 are selectively joined together via integral snap
features as well as retaining clips 312. The snap features and the
clips 312 may be operated to optionally disconnect the left shell
308 from the right shell 310. When joined, left shell 308 and the
right shell 310 may be conceptualized as defining two distinct
functional portions of the blower assembled 130.
[0045] One functional portion of the blower assembly 130 may be
referred to as the blower housing 314. A primary function of the
blower housing 314 is to receive at least a portion of each of the
motor 300 and the impeller 304 while also defining an intermediate
air path between each of the left air input port 316 of the blower
assembly 130 and the right air input port 318 of the blower
assembly 130 and the blower output 320. It is the shape of the
interior of the blower housing 314 in combination with the movement
of the impeller 304 that allows the optional intake of air through
the right air input port 318 and the left air input port 316 and
subsequent output of that air through the blower output 320.
Another functional portion of the blower assembly 130 may be
referred to as the blower deck 322. A first primary function of the
blower deck 322 is to serve as a physical component used in
mounting the entire blower assembly 130 within and relative to the
blower cabinet 102. A second primary function of the blower deck
322 is to serve as a substantial air pressure barrier between the
portion of the interior of the blower cabinet 102 that houses the
blower assembly 130 and the interior of, in this embodiment, the
heat exchanger cabinet 104.
[0046] Because the blower housing 314 in the blower deck 322 are
substantially integrally formed when the left shell 308 is joined
to the right shell 310, the blower housing 314 in the blower deck
322 may be conceptualized as being joined along an interface path
324. In this embodiment, interface path 324 comprises the points at
which an inner surface of the blower assembly 130 begins to
primarily extend at least one of a left, right, front, and/or rear
direction. Accordingly, in this embodiment, the interference path
324 generally denotes a perimeter of the blower output 320.
[0047] The blower deck 322 generally comprises a left floor 326 and
a right floor 328 that extend outward from the blower output 320 in
a substantially left, right, front, and/or rear directions so that
a generally horizontal boundary is formed. The left floor 326
extends generally horizontally outward to meet a left wall 330 of
the blower deck 322, a left portion of a front wall 332 of the
blower deck 322, a left portion of a rear wall 334 of the blower
deck 322, and a left most portion of the right floor 328. The right
floor 328 extends generally horizontally outward to meet a right
wall 336 of the blower deck 322, a right portion of the front wall
332 of the blower deck 322, a right portion of the rear wall 334 of
the blower deck 322, and a right most portion of the left floor
326.
[0048] In this embodiment, the left floor 326 is slightly sloped so
that a left end of the left floor 326 is slightly vertically higher
than a right end of the left floor 326. Similarly, in this
embodiment, the right floor 328 is slightly sloped so that a right
end of the right floor 326 is slightly vertically higher than a
left end of the right floor 328. Further, in this embodiment, a top
edge of the rear wall 334 of the left shell 308 is slightly sloped
so that a right end of the top edge of the rear wall 334 of the
left shell 308 is slightly vertically higher than a left end of the
top edge of the rear wall 334 of the left shell 308. Similarly, in
this embodiment, a top edge of the rear wall 334 of the right shell
310 is slightly sloped so that a left end of the top edge of the
rear wall 334 of the right shell 310 is slightly vertically higher
than a right end of the top edge of the rear wall 334 of the right
shell 310. Still further, in this embodiment, a right end of the
rear wall 334 of the left shell 308 is located slightly further
rearward than a left end of the rear wall 334 of the left shell
308. Similarly, in this embodiment, a left end of the rear wall 334
of the right shell 310 is located slightly further rearward in a
right and of the rear wall 334 of the right shell 310.
[0049] In this embodiment, structural webs 338 are provided to
increase the rigidity and/or strength of the blower assembly 130.
Some structural webs 338 join the left wall 330 to the left floor
326 while other structural webs 338 join the right wall 336 to the
right floor 328. In this embodiment, some structural webs 338 join
the left floor 326 to a left portion of the blower housing 314
while other structural webs 338 join the right floor 328 to a right
portion of the blower housing 314.
[0050] Referring now additionally to FIGS. 13 and 14, a drip shield
340 and a mounting plate 342 are shown in greater detail. FIG. 13
is an oblique partial view of the blower assembly 130 from an
upper-rear-right in viewpoint. FIG. 14 is an oblique partial
exploded view of the blower assembly 130 from a rear-right
viewpoint. FIG. 13 generally shows each of the drip shield 340 and
the mounting plate 342 in their installed positions relative to the
blower deck 322. FIG. 14 generally shows the drip shield 340 and
the mounting plate 342 together in isolation from the remainder of
the blower assembly 130 and in exploded positions relative to each
other so that there is a vertical offset distance between the
two.
[0051] The drip shield 340 comprises a generally horizontal cover
comprising a bent plate 344 having a central ridge 346 extending in
a forward-rearward direction and from such ridge 346 the bent plate
344 extends both in the left direction in the right direction. As
the bent plate 344 extends from the ridge 346 in the left
direction, the bent plate 344 extends slightly downward from the
vertical height of the ridge 346. Similarly, as the bent plate 344
extends from the ridge 346 in the right direction, the bent plate
344 extends slightly downward from the vertical height of the ridge
346. In this embodiment, it will be appreciated that the underside
of the bent plate 344 is dimensioned to complement and accordingly
to optionally mate with the upper end of the front wall 332 of the
blower deck 322. As shown, a rear left corner of the bent plate 344
and a rear right corner of the bent plate 344 are each locally bent
vertically downward. Accordingly, when installed and/or attached to
the blower deck 322, water and/or condensation that contacts the
bent plate 344 from above may tend to drain downward and away from
any electrical components carried by the mounting plate 342. In
some embodiments, water and/or condensation may be routed by the
bent plate 344 toward left floor 326 and the right floor 328 rather
than pooling above any electrical components carried by the
mounting plate 342.
[0052] In this embodiment, the bent plate 344 further comprises a
left tab 348, a right tab 350, and front tabs 352. The left tab 348
extends generally downward from the left side of the bent plate
344. The right tab 350 extends generally downward from the right
side of the bent plate 344. The front tabs 352 extend generally
upward from the front side of the bent plate 344.
[0053] This embodiment, the mounting plate 342 comprises a
generally vertical component wall 354 configured for mounting
against the front wall 332 of the blower deck 322. Mounting plate
342 further comprises forward tabs that extend generally forward
from an upper end of the component wall 354. The upper end of the
mounting plate 342 and the forward tabs 356 are configured to
complement the underside of the bent plate 344 and to mate against
the underside of the bent plate 344.
[0054] Referring now to FIG. 2, it can be seen that when the blower
assembly 130 is installed into the blower cabinet 102, the blower
deck 322 generally provides a zone boundary 358 between a first
interior zone 360 of the AHU 100 and a second interior zone 362 of
the AHU 100. The first interior zone 360 is generally associated
with the left and right air input ports 316, 318 of the blower
assembly 130 while the second interior zone 362 is generally
associated with a space adjacent the blower output 320 and which,
in this embodiment, is generally associated with the coil assembly
128. More specifically, in this embodiment, the left and right
floors 326, 328 of the blower deck 322 generally divide the
interior of the AHU 100 into the first and second interior zones
360, 362 so that operation of the motor 300 to rotate the impeller
304 may cause a pressure differential between the zones 360,
362.
[0055] In this embodiment, the blower deck 322 does not provide the
entire zone boundary 358, but rather, the zone boundary 358 is at
least partially defined by the drip shield 340. More specifically,
in this embodiment, the zone boundary 358 comprises the left floor
326, the right floor 328, and the bent plate 344. Of course in
other embodiments, the blower deck 322 may be configured to
incorporate the functionality of the drip shield into the blower
deck 322 itself as a unitary component. Nonetheless, this
disclosure provides a blower assembly 130 that comprises components
that form an entire zone boundary 358 when the blower assembly 130
is installed into the AHU 100.
[0056] More particularly, when the blower assembly 130 is installed
into the AHU 100, the following components may be mated and/or
located adjacent each other to produce the zone boundary 358: the
rear wall 334 and the interior rear surface 156 and/or mounting
channels 230, the right wall 336 and the right interior side
surfaces 154 and/or mounting channels 230, the left wall 330 and
the left interior side surfaces 154 and/or mounting channels 230,
the upper end of the front wall 332 and the underside of the bent
plate 344 of the drip shield 340, the front tabs 352 of the drip
shield 340 and the back side of the blower cabinet panel 120, the
left tab 348 of the drip shield 340 and the left interior side
surface 154 and/or mounting channels 230, and the right tab 350 of
the drip shield 340 and the right interior side surface 154 and/or
mounting channels 230.
[0057] In some embodiments, a center of mass and/or a center of
gravity of the blower assembly 130 is located within a periphery
the components that form the zone boundary 358, as viewed from
above. In some cases, by locating the center of mass and/or center
of gravity in the above described manner may allow better
distribution of forces due to gravity along a greater footprint so
that gravitational forces do not consistently produce large bending
moments against a blower deck that is not integral to a blower
assembly.
[0058] At least one embodiment is disclosed and variations,
combinations, and/or modifications of the embodiment(s) and/or
features of the embodiment(s) made by a person having ordinary
skill in the art are within the scope of the disclosure.
Alternative embodiments that result from combining, integrating,
and/or omitting features of the embodiment(s) are also within the
scope of the disclosure. Where numerical ranges or limitations are
expressly stated, such express ranges or limitations should be
understood to include iterative ranges or limitations of like
magnitude falling within the expressly stated ranges or limitations
(e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater
than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a
numerical range with a lower limit, RI, and an upper limit, Ru, is
disclosed, any number falling within the range is specifically
disclosed. In particular, the following numbers within the range
are specifically disclosed: R=RI+k*(Ru-RI), wherein k is a variable
ranging from 1 percent to 100 percent with a 1 percent increment,
i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, .
. . 50 percent, 51 percent, 52 percent, . . . , 95 percent, 96
percent, 97 percent, 98 percent, 99 percent, or 100 percent.
Moreover, any numerical range defined by two R numbers as defined
in the above is also specifically disclosed. Use of the term
"optionally" with respect to any element of a claim means that the
element is required, or alternatively, the element is not required,
both alternatives being within the scope of the claim. Use of
broader terms such as comprises, includes, and having should be
understood to provide support for narrower terms such as consisting
of, consisting essentially of, and comprised substantially of.
Accordingly, the scope of protection is not limited by the
description set out above but is defined by the claims that follow,
that scope including all equivalents of the subject matter of the
claims. Each and every claim is incorporated as further disclosure
into the specification and the claims are embodiment(s) of the
present invention.
* * * * *