U.S. patent application number 15/818813 was filed with the patent office on 2019-05-23 for fan assembly for a packaged terminal air conditioner unit.
The applicant listed for this patent is Haier US Appliance Solutions, Inc.. Invention is credited to Richard Dustin Henderson, Robert William Jewell, Richard Michael Phillips.
Application Number | 20190154299 15/818813 |
Document ID | / |
Family ID | 66532785 |
Filed Date | 2019-05-23 |
![](/patent/app/20190154299/US20190154299A1-20190523-D00000.png)
![](/patent/app/20190154299/US20190154299A1-20190523-D00001.png)
![](/patent/app/20190154299/US20190154299A1-20190523-D00002.png)
![](/patent/app/20190154299/US20190154299A1-20190523-D00003.png)
![](/patent/app/20190154299/US20190154299A1-20190523-D00004.png)
![](/patent/app/20190154299/US20190154299A1-20190523-D00005.png)
![](/patent/app/20190154299/US20190154299A1-20190523-D00006.png)
![](/patent/app/20190154299/US20190154299A1-20190523-D00007.png)
![](/patent/app/20190154299/US20190154299A1-20190523-D00008.png)
![](/patent/app/20190154299/US20190154299A1-20190523-D00009.png)
![](/patent/app/20190154299/US20190154299A1-20190523-D00010.png)
View All Diagrams
United States Patent
Application |
20190154299 |
Kind Code |
A1 |
Jewell; Robert William ; et
al. |
May 23, 2019 |
FAN ASSEMBLY FOR A PACKAGED TERMINAL AIR CONDITIONER UNIT
Abstract
A packaged terminal air conditioner unit (PTAC) includes a vent
aperture defined in a bulkhead of the PTAC and a fan assembly for
urging a flow of make-up air through the vent aperture. The fan
assembly includes a fan duct attached to the bulkhead and defining
a flow passage in fluid communication with the vent aperture and an
auxiliary fan mounted to the fan duct for urging the flow of
make-up air through the vent aperture. An isolation member formed
from a resilient material, such as an elastomeric or rubber
material, is positioned between the auxiliary fan and the fan duct
to reduce vibrations generated by the auxiliary fan.
Inventors: |
Jewell; Robert William;
(Louisville, KY) ; Phillips; Richard Michael;
(Louisville, KY) ; Henderson; Richard Dustin;
(LaGrange, KY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Haier US Appliance Solutions, Inc. |
Wilmington |
DE |
US |
|
|
Family ID: |
66532785 |
Appl. No.: |
15/818813 |
Filed: |
November 21, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24F 1/027 20130101;
F24F 13/20 20130101; F24F 1/029 20190201; F24F 2013/242 20130101;
F24F 13/24 20130101; F24F 7/10 20130101; F24F 2013/205
20130101 |
International
Class: |
F24F 13/24 20060101
F24F013/24; F24F 7/10 20060101 F24F007/10 |
Claims
1. A packaged terminal air conditioner unit comprising: a bulkhead
defining an indoor portion and an outdoor portion; a vent aperture
defined in the bulkhead; a fan duct attached to the bulkhead and
defining a flow passage in fluid communication with the vent
aperture; an auxiliary fan mounted to the fan duct and being
configured for urging a flow of make-up air from the outdoor
portion through the flow passage and the vent aperture to the
indoor portion; and an isolation member positioned between the
auxiliary fan and the fan duct.
2. The packaged terminal air conditioner unit of claim 1, wherein
the isolation member is formed from an elastomeric or rubber
material.
3. The packaged terminal air conditioner unit of claim 1, wherein
the auxiliary fan defines a fan perimeter, the isolation member
extending around the entire fan perimeter.
4. The packaged terminal air conditioner unit of claim 3, wherein
the isolation member defines an inner surface and a plurality of
complementary mating features extending from the inner surface
toward the auxiliary fan for securing the auxiliary fan.
5. The packaged terminal air conditioner unit of claim 4, wherein
the complementary mating features are arcuate for engaging the fan
perimeter.
6. The packaged terminal air conditioner unit of claim 4, wherein
isolation member is substantially rectangular and includes four
sides, and wherein the plurality of complementary mating features
comprises four complementary mating features defined on the four
side of the isolation member.
7. The packaged terminal air conditioner unit of claim 4, wherein
the auxiliary fan defines an upstream flange and a downstream
flange separated along an axial direction by a flange gap, and
wherein the complementary mating features are positioned within the
flange gap to fix the position of the auxiliary fan along the axial
direction.
8. The packaged terminal air conditioner unit of claim 7, wherein
the flange gap defines a gap width along the axial direction and
the complementary mating features define a feature width along the
axial direction, the gap width being substantially the same as the
feature width.
9. The packaged terminal air conditioner unit of claim 1, wherein
fan duct comprises a lower portion defining a lower bracket and an
upper portion defining an upper bracket, and wherein the isolation
member defines an outer surface for contacting the fan duct and an
isolation flange extending from the outer surface and being
positioned between the lower bracket and the upper bracket of the
fan duct.
10. The packaged terminal air conditioner unit of claim 9, wherein
the lower portion and the upper portion are joined by mechanical
fasteners, the mechanical fasteners passing through screw holes
defined in the lower bracket, the upper bracket, and the isolation
flange.
11. The packaged terminal air conditioner of claim 1, comprising: a
fan mounting structure configured for receiving the auxiliary fan
and the isolation member, the fan mounting structure being attached
to the fan duct.
12. The packaged terminal air conditioner unit of claim 1, wherein
the fan duct is positioned within the outdoor portion of the
packaged terminal air conditioner unit.
13. The packaged terminal air conditioner unit of claim 1, wherein
the fan duct defines an inlet and an outlet, the auxiliary fan
being positioned at the inlet and the outlet being attached to the
bulkhead.
14. The packaged terminal air conditioner unit of claim 1, wherein
the auxiliary fan is an axial fan.
15. A fan assembly for a packaged terminal air conditioner unit,
the packaged terminal air conditioner unit comprising a bulkhead
defining a vent aperture, the fan assembly comprising: a fan duct
attached to the bulkhead and defining a flow passage in fluid
communication with the vent aperture; an auxiliary fan mounted to
the fan duct and being configured for urging a flow of make-up air
through the vent aperture; and an isolation member positioned
between the auxiliary fan and the fan duct.
16. The fan assembly of claim 15, wherein the isolation member is
formed from an elastomeric or rubber material.
17. The fan assembly of claim 15, wherein the auxiliary fan defines
a fan perimeter, the isolation member extending around the entire
fan perimeter.
18. The fan assembly of claim 17, wherein the isolation member
defines an inner surface and a plurality of complementary mating
features extending from the inner surface toward the auxiliary fan
for securing the auxiliary fan.
19. The fan assembly of claim 15, wherein fan duct comprises a
lower portion defining a lower bracket and an upper portion
defining an upper bracket, and wherein the isolation member defines
an outer surface for contacting the fan duct and an isolation
flange extending from the outer surface and being positioned
between the lower bracket and the upper bracket of the fan
duct.
20. The fan assembly of claim 15, wherein the fan duct defines an
inlet and an outlet, the auxiliary fan being positioned at the
inlet and the outlet being attached to the bulkhead.
Description
FIELD OF THE INVENTION
[0001] The present disclosure relates generally to air conditioner
units, and more particularly to fan assemblies for providing
make-up air to packaged terminal air conditioner units.
BACKGROUND OF THE INVENTION
[0002] Air conditioner or conditioning units are conventionally
utilized to adjust the temperature indoors--i.e. within structures
such as dwellings and office buildings. Such units commonly include
a closed refrigeration loop to heat or cool the indoor air.
Typically, the indoor air is recirculated while being heated or
cooled. A variety of sizes and configurations are available for
such air conditioner units. For example, some units may have one
portion installed within the indoors that is connected, by e.g.,
tubing carrying the refrigerant, to another portion located
outdoors. These types of units are typically used for conditioning
the air in larger spaces.
[0003] Another type of unit, sometimes referred to as a packaged
terminal air conditioner unit (PTAC), may be used for somewhat
smaller indoor spaces that are to be air conditioned. These units
may include both an indoor portion and an outdoor portion separated
by a bulkhead and may be installed in windows or positioned within
an opening of an exterior wall of a building. PTACs often need to
draw air from the outdoor portion into the indoor portion.
Accordingly, certain PTACs allow for the introduction of make-up
air into the indoor space, e.g., through a vent aperture defined in
the bulkhead that separates the indoor and outdoor side of the
unit.
[0004] Conventional PTACs may further include an auxiliary fan
and/or make-up air module fluidly coupled with the vent aperture to
urge a flow of make-up air from the outdoor side of the PTAC into
the conditioned room. However, attaching a fan to the bulkhead can
induce structure-born noise into system the PTAC. Increased noise
can be a nuisance to occupants of the conditioned room or otherwise
result in a less desirable consumer experience. Therefore, sound
penetration into the room is preferably minimized.
[0005] Accordingly, improved air conditioner units and fan
assemblies for providing make-up air would be useful. More
specifically, a fan assembly for a packaged terminal air
conditioner unit that can supply the requested make-up air while
reducing auxiliary fan noise would be particularly beneficial.
BRIEF DESCRIPTION OF THE INVENTION
[0006] The present subject matter provides a packaged terminal air
conditioner unit (PTAC) including a vent aperture defined in a
bulkhead of the PTAC and a fan assembly for urging a flow of
make-up air through the vent aperture. The fan assembly includes a
fan duct attached to the bulkhead and defining a flow passage in
fluid communication with the vent aperture and an auxiliary fan
mounted to the fan duct for urging the flow of make-up air through
the vent aperture. An isolation member formed from a resilient
material, such as an elastomeric or rubber material, is positioned
between the auxiliary fan and the fan duct to reduce vibrations
generated by the auxiliary fan. Additional aspects and advantages
of the invention will be set forth in part in the following
description, may be obvious from the description, or may be learned
through practice of the invention.
[0007] In accordance with one embodiment, a packaged terminal air
conditioner unit includes a bulkhead defining an indoor portion and
an outdoor portion and a vent aperture defined in the bulkhead. A
fan duct is attached to the bulkhead and defines a flow passage in
fluid communication with the vent aperture. An auxiliary fan is
mounted to the fan duct and is configured for urging a flow of
make-up air from the outdoor portion through the flow passage and
the vent aperture to the indoor portion. An isolation member is
positioned between the auxiliary fan and the fan duct.
[0008] In accordance with another embodiment, a fan assembly for a
packaged terminal air conditioner unit is provided. The packaged
terminal air conditioner unit includes a bulkhead defining a vent
aperture. The fan assembly includes a fan duct attached to the
bulkhead and defining a flow passage in fluid communication with
the vent aperture. An auxiliary fan is mounted to the fan duct and
is configured for urging a flow of make-up air through the vent
aperture. An isolation member is positioned between the auxiliary
fan and the fan duct.
[0009] These and other features, aspects and advantages of the
present invention will become better understood with reference to
the following description and appended claims. The accompanying
drawings, which are incorporated in and constitute a part of this
specification, illustrate embodiments of the invention and,
together with the description, serve to explain the principles of
the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A full and enabling disclosure of the present invention,
including the best mode thereof, directed to one of ordinary skill
in the art, is set forth in the specification, which makes
reference to the appended figures.
[0011] FIG. 1 provides a perspective view of an air conditioner
unit, with part of an indoor portion exploded from a remainder of
the air conditioner unit for illustrative purposes, in accordance
with one exemplary embodiment of the present disclosure.
[0012] FIG. 2 is another perspective view of components of the
indoor portion of the exemplary air conditioner unit of FIG. 1.
[0013] FIG. 3 is a schematic view of a refrigeration loop in
accordance with one embodiment of the present disclosure.
[0014] FIG. 4 is a rear perspective view of an outdoor portion of
the exemplary air conditioner unit of FIG. 1, illustrating a vent
aperture in a bulkhead in accordance with one embodiment of the
present disclosure.
[0015] FIG. 5 is a front perspective view of the exemplary bulkhead
of FIG. 4 with a vent door illustrated in the open position in
accordance with one embodiment of the present disclosure.
[0016] FIG. 6 is a rear perspective view of the exemplary air
conditioner unit and bulkhead of FIG. 4 including a fan assembly
for providing make-up air in accordance with one embodiment of the
present disclosure.
[0017] FIG. 7 is a top view of components of the exemplary air
conditioner unit of FIG. 1 according to an exemplary embodiment of
the present subject matter.
[0018] FIG. 8 depicts close-up perspective view of the exemplary
fan assembly of FIG. 6 according to example embodiments of the
present subject matter.
[0019] FIG. 9 provides a top, cross sectional view of the exemplary
air conditioner unit of FIG. 1 and the exemplary fan assembly of
FIG. 6.
[0020] FIG. 10 provides a rear view of the exemplary air
conditioner unit of FIG. 1 and the exemplary fan assembly of FIG. 6
with an auxiliary fan illustrated in phantom.
[0021] FIG. 11 provides a perspective view of a fan duct of the
exemplary fan assembly of FIG. 6 according to an exemplary
embodiment of the present subject matter.
[0022] FIG. 12 provides an exploded view of the exemplary fan duct
of FIG. 11.
[0023] FIG. 13 provides a partially exploded view of the exemplary
fan assembly of FIG. 6.
[0024] FIG. 14 provides a perspective view of an auxiliary fan that
may be used with the exemplary fan assembly of FIG. 6.
[0025] FIG. 15 provides an exploded view of an electronics assembly
of the exemplary fan assembly of FIG. 6.
[0026] FIG. 16 provides a front perspective view of an electronics
enclosure of the exemplary electronics assembly of FIG. 15.
[0027] FIG. 17 provides a rear perspective view of the exemplary
electronics enclosure of FIG. 16.
[0028] Repeat use of reference characters in the present
specification and drawings is intended to represent the same or
analogous features or elements of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Reference now will be made in detail to embodiments of the
invention, one or more examples of which are illustrated in the
drawings. Each example is provided by way of explanation of the
invention, not limitation of the invention. In fact, it will be
apparent to those skilled in the art that various modifications and
variations can be made in the present invention without departing
from the scope or spirit of the invention. For instance, features
illustrated or described as part of one embodiment can be used with
another embodiment to yield a still further embodiment. Thus, it is
intended that the present invention covers such modifications and
variations as come within the scope of the appended claims and
their equivalents.
[0030] Referring now to FIGS. 1 and 2, an air conditioner unit 10
is provided. The air conditioner unit 10 is a one-unit type air
conditioner, also conventionally referred to as a room air
conditioner or a packaged terminal air conditioner (PTAC). The unit
10 includes an indoor portion 12 and an outdoor portion 14, and
generally defines a vertical direction V, a lateral direction L,
and a transverse direction T. Each direction V, L, T is
perpendicular to each other, such that an orthogonal coordinate
system is generally defined.
[0031] A housing 20 of the unit 10 may contain various other
components of the unit 10. Housing 20 may include, for example, a
rear grill 22 and a room front 24 which may be spaced apart along
the transverse direction T by a wall sleeve 26. The rear grill 22
may be part of the outdoor portion 14, and the room front 24 may be
part of the indoor portion 12. Components of the outdoor portion
14, such as an outdoor heat exchanger 30, an outdoor fan 32, and a
compressor 34 may be housed within the wall sleeve 26. A fan shroud
36 may additionally enclose outdoor fan 32, as shown.
[0032] Indoor portion 12 may include, for example, an indoor heat
exchanger 40, a blower fan or indoor fan 42, and a heating unit 44.
These components may, for example, be housed behind the room front
24. Additionally, a bulkhead 46 may generally support and/or house
various other components or portions thereof of the indoor portion
12, such as indoor fan 42 and the heating unit 44. Bulkhead 46 may
generally separate and define the indoor portion 12 and outdoor
portion 14.
[0033] Outdoor and indoor heat exchangers 30, 40 may be components
of a refrigeration loop 48, which is shown schematically in FIG. 3.
Refrigeration loop 48 may, for example, further include compressor
34 and an expansion device 50. As illustrated, compressor 34 and
expansion device 50 may be in fluid communication with outdoor heat
exchanger 30 and indoor heat exchanger 40 to flow refrigerant
therethrough as is generally understood. More particularly,
refrigeration loop 48 may include various lines for flowing
refrigerant between the various components of refrigeration loop
48, thus providing the fluid communication there between.
Refrigerant may thus flow through such lines from indoor heat
exchanger 40 to compressor 34, from compressor 34 to outdoor heat
exchanger 30, from outdoor heat exchanger 30 to expansion device
50, and from expansion device 50 to indoor heat exchanger 40. The
refrigerant may generally undergo phase changes associated with a
refrigeration cycle as it flows to and through these various
components, as is generally understood. Suitable refrigerants for
use in refrigeration loop 48 may include pentafluoroethane,
difluoromethane, or a mixture such as R410a, although it should be
understood that the present disclosure is not limited to such
example and rather that any suitable refrigerant may be
utilized.
[0034] As is understood in the art, refrigeration loop 48 may be
alternately be operated as a refrigeration assembly (and thus
perform a refrigeration cycle) or a heat pump (and thus perform a
heat pump cycle). As shown in FIG. 3, when refrigeration loop 48 is
operating in a cooling mode and thus performs a refrigeration
cycle, the indoor heat exchanger 40 acts as an evaporator and the
outdoor heat exchanger 30 acts as a condenser. Alternatively, when
the assembly is operating in a heating mode and thus performs a
heat pump cycle, the indoor heat exchanger 40 acts as a condenser
and the outdoor heat exchanger 30 acts as an evaporator. The
outdoor and indoor heat exchangers 30, 40 may each include coils
through which a refrigerant may flow for heat exchange purposes, as
is generally understood.
[0035] According to an example embodiment, compressor 34 may be a
variable speed compressor. In this regard, compressor 34 may be
operated at various speeds depending on the current air
conditioning needs of the room and the demand from refrigeration
loop 48. For example, according to an exemplary embodiment,
compressor 34 may be configured to operate at any speed between a
minimum speed, e.g., 1500 revolutions per minute (RPM), to a
maximum rated speed, e.g., 3500 RPM. Notably, use of variable speed
compressor 34 enables efficient operation of refrigeration loop 48
(and thus air conditioner unit 10), minimizes unnecessary noise
when compressor 34 does not need to operate at full speed, and
ensures a comfortable environment within the room.
[0036] In exemplary embodiments as illustrated, expansion device 50
may be disposed in the outdoor portion 14 between the indoor heat
exchanger 40 and the outdoor heat exchanger 30. According to the
exemplary embodiment, expansion device 50 may be an electronic
expansion valve that enables controlled expansion of refrigerant,
as is known in the art. More specifically, electronic expansion
device 50 may be configured to precisely control the expansion of
the refrigerant to maintain, for example, a desired temperature
differential of the refrigerant across the indoor heat exchanger
40. In other words, electronic expansion device 50 throttles the
flow of refrigerant based on the reaction of the temperature
differential across indoor heat exchanger 40 or the amount of
superheat temperature differential, thereby ensuring that the
refrigerant is in the gaseous state entering compressor 34.
According to alternative embodiments, expansion device 50 may be a
capillary tube or another suitable expansion device configured for
use in a thermodynamic cycle.
[0037] According to the illustrated exemplary embodiment, outdoor
fan 32 is an axial fan and indoor fan 42 is a centrifugal fan.
However, it should be appreciated that according to alternative
embodiments, outdoor fan 32 and indoor fan 42 may be any suitable
fan type. In addition, according to an exemplary embodiment,
outdoor fan 32 and indoor fan 42 are variable speed fans. For
example, outdoor fan 32 and indoor fan 42 may rotate at different
rotational speeds, thereby generating different air flow rates. It
may be desirable to operate fans 32, 42 at less than their maximum
rated speed to ensure safe and proper operation of refrigeration
loop 48 at less than its maximum rated speed, e.g., to reduce noise
when full speed operation is not needed. In addition, according to
alternative embodiments, fans 32, 42 may be operated to urge
make-up air into the room.
[0038] According to the illustrated embodiment, indoor fan 42 may
operate as an evaporator fan in refrigeration loop 48 to encourage
the flow of air through indoor heat exchanger 40. Accordingly,
indoor fan 42 may be positioned downstream of indoor heat exchanger
40 along the flow direction of indoor air and downstream of heating
unit 44. Alternatively, indoor fan 42 may be positioned upstream of
indoor heat exchanger 40 along the flow direction of indoor air,
and may operate to push air through indoor heat exchanger 40.
[0039] Heating unit 44 in exemplary embodiments includes one or
more heater banks 60. Each heater bank 60 may be operated as
desired to produce heat. In some embodiments as shown, three heater
banks 60 may be utilized. Alternatively, however, any suitable
number of heater banks 60 may be utilized. Each heater bank 60 may
further include at least one heater coil or coil pass 62, such as
in exemplary embodiments two heater coils or coil passes 62.
Alternatively, other suitable heating elements may be utilized.
[0040] The operation of air conditioner unit 10 including
compressor 34 (and thus refrigeration loop 48 generally) indoor fan
42, outdoor fan 32, heating unit 44, expansion device 50, and other
components of refrigeration loop 48 may be controlled by a
processing device such as a controller 64. Controller 64 may be in
communication (via for example a suitable wired or wireless
connection) to such components of the air conditioner unit 10.
Controller 64 may include a memory and one or more processing
devices such as microprocessors, CPUs or the like, such as general
or special purpose microprocessors operable to execute programming
instructions or micro-control code associated with operation of
unit 10. The memory may represent random access memory such as
DRAM, or read only memory such as ROM or FLASH. In one embodiment,
the processor executes programming instructions stored in memory.
The memory may be a separate component from the processor or may be
included onboard within the processor.
[0041] Unit 10 may additionally include a control panel 66 and one
or more user inputs 68, which may be included in control panel 66.
The user inputs 68 may be in communication with the controller 64.
A user of the unit 10 may interact with the user inputs 68 to
operate the unit 10, and user commands may be transmitted between
the user inputs 68 and controller 64 to facilitate operation of the
unit 10 based on such user commands. A display 70 may additionally
be provided in the control panel 66, and may be in communication
with the controller 64. Display 70 may, for example be a
touchscreen or other text-readable display screen, or alternatively
may simply be a light that can be activated and deactivated as
required to provide an indication of, for example, an event or
setting for the unit 10.
[0042] Referring briefly to FIG. 4, a vent aperture 80 may be
defined in bulkhead 46 providing fluid communication between indoor
portion 12 and outdoor portion 14. Vent aperture 80 may be utilized
in an installed air conditioner unit 10 to allow outdoor air to
flow into the room through the indoor portion 12. In this regard,
in some cases it may be desirable to allow outside air (i.e.,
"make-up air") to flow into the room in order, e.g., to meet
government regulations, to compensate for negative pressure created
within the room, etc. In this manner, according to an exemplary
embodiment, make-up air may be provided into the room through vent
aperture 80 when desired.
[0043] As shown in FIG. 5, a vent door 82 may be pivotally mounted
to the bulkhead 46 proximate to vent aperture 80 to open and close
vent aperture 80. More specifically, as illustrated, vent door 82
is pivotally mounted to the indoor facing surface of indoor portion
12. Vent door 82 may be configured to pivot between a first, closed
position where vent door 82 prevents air from flowing between
outdoor portion 14 and indoor portion 12, and a second, open
position where vent door 82 is in an open position (as shown in
FIG. 5) and allows make-up air to flow into the room. According to
the illustrated embodiment vent door 82 may be pivoted between the
open and closed position by an electric motor 84 controlled by
controller 64, or by any other suitable method.
[0044] In some cases, it may be desirable to treat or condition
make-up air flowing through vent aperture 80 prior to blowing it
into the room. For example, outdoor air which has a relatively high
humidity level may require treating before passing into the room.
In addition, if the outdoor air is cool, it may be desirable to
heat the air before blowing it into the room. Therefore, according
to an exemplary embodiment of the present subject matter, unit 10
may further include an auxiliary sealed system that is positioned
over vent aperture 80 for conditioning make-up air. The auxiliary
sealed system may be a miniature sealed system that acts similar to
refrigeration loop 48, but conditions only the air flowing through
vent aperture 80. According to alternative embodiments, such as
that described herein, make-up air may be urged through vent
aperture 80 without the assistance of an auxiliary sealed system.
Instead, make-up air is urged through vent aperture 80 may be
conditioned at least in part by refrigeration loop 48, e.g., by
passing through indoor heat exchanger 40. Additionally, the make-up
air may be conditioned immediately upon entrance through vent
aperture 80 or sequentially after combining with the air stream
induced through indoor heat exchanger 40.
[0045] Referring now to FIGS. 6 through 10, a fan assembly 100 will
be described according to an exemplary embodiment of the present
subject matter. According to the illustrated embodiment, fan
assembly 100 is generally configured for urging the flow of makeup
air through vent aperture 80 and into a conditioned room without
the assistance of an auxiliary sealed system. However, should be
appreciated that fan assembly 100 is described herein for the
purpose of explaining aspects of the present subject, and that
variations and modifications may be made to fan assembly 100 while
remaining within scope of the present subject matter. In this
regard, fan assembly 100 could be used in conjunction with a
make-up air module including an auxiliary sealed system for
conditioning the flow of make-up air.
[0046] As illustrated, fan assembly 100 includes a fan duct 102
that defines a flow passage 104 that is in fluid communication with
vent aperture 80. In this manner, the flow of makeup air may pass
through flow passage 104 and vent aperture 80 into the conditioned
room or indoor portion 12. More specifically, fan duct 102 may
define an inlet 106 and an outlet 108 spaced apart from each other
along the transverse direction T. Outlet 108 of fan duct 102 is
attached to bulkhead 46 of air conditioner unit 10 to fluidly
couple flow passage 104 to vent aperture 80. As will be described
in detail below, inlet 106 of fan duct 102 extends away from
bulkhead 46 toward rear grill 22 of air conditioner unit 10.
[0047] According to the illustrated embodiment, an auxiliary fan
120 is mounted to fan duct 102 and is generally configured for
urging a flow of makeup air (as indicated by arrows labeled with
reference numeral 122 in FIG. 7) from outdoor portion 14 through
flow passage 104 and vent aperture 80 to indoor portion 12.
According to the illustrated embodiment, auxiliary fan 120 is an
axial fan. For example, one exemplary axial fan that may be used
with fan assembly will be described below in reference to FIG. 14.
However, it should be appreciated that any other suitable number,
type, and configuration of fan or blower could be used to urge a
flow of makeup air according to alternative embodiments.
[0048] As illustrated, auxiliary fan 120 is positioned at inlet 106
of fan duct 102, e.g., remote from outlet 108. In addition, fan
assembly 100 (including fan duct 102 and auxiliary fan 120) is
illustrated as being positioned within outdoor portion 14 of air
conditioner unit 10. However, it should be appreciated that fan
assembly 100 may be positioned in any other suitable location
within air conditioner unit 10 and auxiliary fan 120 may be
positioned at any other suitable location within or in fluid
communication with fan duct 102. The embodiments described herein
are only exemplary and are not intended to limit the scope present
subject matter.
[0049] As best shown in FIG. 7, outdoor air (as indicated by arrows
labeled with reference numeral 124) is circulated through outdoor
heat exchanger 30 using outdoor fan 32. More specifically, outdoor
fan 32 is surrounded by fan shroud 36 that defines a shroud inlet
126 positioned closer to bulkhead 46 relative to a discharge 128
defined adjacent rear grill 22. In this manner, outdoor fan 32
urges a flow of outdoor air 124 in through rear grill 22 around
lateral sides of air conditioner unit 10 and fan shroud 36. The
outdoor air is drawn toward shroud inlet 126 and discharged through
outdoor heat exchanger 30 and out rear grill 22. Notably, outdoor
fan 32 tends to generate negative pressure within outdoor portion
14, particularly in regions closer to shroud inlet 126, bulkhead
46, or vent aperture 80. The negative pressure tends to develop or
increase as the outdoor air 124 approaches shroud inlet 126.
[0050] According to an exemplary embodiment of the present subject
matter, fan duct 102 may define a geometry and be positioned such
that inlet 106 is positioned at a location where the negative
pressure generated by outdoor fan 32 does not significantly affect
the ability of auxiliary fan 120 to draw make-up air 122 into flow
passage 104. In this manner, for example, fan duct 102 may extend
towards rear grill 22 such that inlet 106 is positioned proximate
rear grill 22. According to an exemplary embodiment, inlet 106 may
be directly coupled to or defined by rear grill 22. Notably, such
positioning of inlet 106 allows auxiliary fan 120 to draw in
make-up air 122 without having to compete with outdoor fan 32.
[0051] Referring now specifically to FIGS. 6 through 9, inlet 106
of fan duct 102 may be positioned between a rear 130 of air
conditioner unit 10 and shroud inlet 126 of fan shroud 36 along the
transverse direction T. According still another embodiment, air
conditioner unit 10 may define an outside depth 132 between
bulkhead 46 and rear grill 22 along the transverse direction T. In
addition, the duct length 134 may be defined between inlet 106 and
outlet 108 of fan duct 102 along the transverse direction.
According to an exemplary embodiment, duct length 134 is greater
than or equal to one quarter of outside depth 132, or greater than
one half of outside depth 132. Other suitable lengths of fan duct
102 are possible and within scope of the present subject
matter.
[0052] Referring now specifically to FIGS. 7, 9, and 10, fan duct
102 may further be shaped to provide sufficient distance between
inlet 106 and shroud inlet 126, e.g., to avoid the negative
pressure generated by outdoor fan 32 and to prevent the propagation
of noise through fan duct 102. In this regard, the inventors the
present subject matter have determined that forming an asymmetric
duct that breaks some or all direct line of sight from inlet 106 to
outlet 108 may reduce noise transmitted to indoor portion 12.
Therefore, according to the illustrated embodiment, fan duct 102 is
asymmetric when viewed along a horizontal plane (e.g., defined by
lateral direction L and transverse direction T) such that inlet 106
and outlet 108 are offset along the transverse direction T. In this
regard, according to one exemplary embodiment, there is limited
line of sight from inlet 106 to outlet 108 of fan duct 102. For
example, as shown in FIG. 10, only a fraction of vent aperture 80
may be seen through inlet 106 when looking along the transverse
direction T (such as less than 25 percent, 10 percent, or even less
than 5 percent of the total area of vent aperture 80). According to
another embodiment, there is no direct line of sight from inlet 106
to outlet 108 along the transverse direction T.
[0053] Notably, fan duct 102 may be formed by injection molding,
e.g., using a suitable plastic material, such as injection molding
grade high impact polystyrene (HIPS) or acrylonitrile butadiene
styrene (ABS). Alternatively, according to the exemplary
embodiment, fan duct 102 is compression molded, e.g., using sheet
molding compound (SMC) thermoset plastic. However, difficulties may
arise in using such manufacturing techniques due to the complex
geometry of fan duct 102. For example, some mold tools may not be
capable of forming an asymmetric fan duct in one piece without
complex tooling, post processing, or other manufacturing
procedures. Therefore, according to an exemplary embodiment of the
present subject matter, fan duct 102 includes an upper portion 140
and a lower portion 142 that are separately formed, e.g., via
compression molding, and are subsequently joined to form fan duct
102.
[0054] More specifically, referring to FIGS. 11 and 12, upper
portion 140 may be an upper half of fan duct 102 and lower portion
142 may be lower half of fan duct 102. To facilitate the joining of
upper portion 140 and lower portion 142, upper portion 140 may
define an upper flange 144 and lower portion 142 may define a lower
flange 146 that extend along a length of fan duct 102. Upper flange
144 and lower flange 146 may be joined together in any suitable
manner. For example, upper flange 144 and lower flange 146 may be
joined using one or more mechanical fasteners, such as screws,
bolts, rivets, etc. Alternatively, glue, welding, snap-fit
mechanisms, interference-fit mechanisms, or any suitable
combination thereof may join upper flange 144 and lower flange
146.
[0055] According to the illustrated embodiment, upper flange 144
and lower flange 146 are joined using an adhesive. In this regard,
upper flange 144 may define an upper channel 148 and lower flange
146 may define a lower channel 150 which are shaped for receiving
an adhesive. During assembly, the upper channel 148 and the lower
channel 150 are filled with adhesive and upper flange 144 is
clamped together with lower flange 146 until the adhesive cures to
form fan duct 102.
[0056] According to an exemplary embodiment, fan assembly 100 may
further include an isolation member 160 that is positioned between
auxiliary fan 120 and fan duct 102. Isolation member 160 may be
formed from an elastomeric or rubber material, such as silicone or
a thermoplastic elastomer. In general, isolation member 160 is
designed to absorb vibrations generated by auxiliary fan 120 during
operation. In this manner, isolation member 160 prevents these
vibrations from propagating through fan duct 102 and generating
noise inside indoor portion 12.
[0057] Referring specifically to FIGS. 11 through 13, isolation
member 160 is positioned around auxiliary fan 120 and within fan
duct 102. In this regard, for example, isolation member 160
generally defines an inner surface 162 and an outer surface 164.
Inner surface 162 is configured for engaging auxiliary fan 120 and
outer surface 164 is configured for engaging fan duct 102. More
specifically, to couple isolation member 160 to fan duct 102, upper
portion 140 of fan duct 102 may further define an upper bracket 166
and lower portion 142 of fan duct 102 may further define a lower
bracket 168. When upper portion 140 and lower portion 142 are
joined to form fan duct 102, a bracket gap 169 (see FIG. 11) is
defined between upper bracket 166 and lower bracket 168.
[0058] Isolation member 160 further defines one or more isolation
flanges 170 which are sized for receipt in bracket gap 169 between
upper bracket 166 and lower bracket 168. In addition, screw holes
172 may be defined through upper bracket 166, lower bracket 168,
and isolation flange 170 for receiving a mechanical fastener. In
this manner, isolation member 160 may be secured within fan duct
102. Although upper portion 140 and lower portion 142 of fan duct
102 are illustrated herein as being joined both by an adhesive and
a mechanical fastener, it should be appreciated that any suitable
means for connecting the two may be used according to alternative
embodiments. For example, upper bracket 166 and lower bracket 168
could instead be extensions of flanges 144, 146 and could be
assembled using an adhesive.
[0059] According to the illustrated embodiment, auxiliary fan 120
defines an axial direction A, a radial direction R, and a
circumferential direction C. In addition, auxiliary fan 120 defines
a fan perimeter 180 which is substantially circular and positioned
between an upstream flange 182 and a downstream flange 184 which
are separated along the axial direction A. According to the
illustrated embodiment, isolation member 160 extends all the way
around the entire fan perimeter 180. More specifically, isolation
member 160 is substantially rectangular and includes four sides.
Isolation member 160 further defines a plurality of complementary
mating features 190 that extend from inner surface 162 toward
auxiliary fan 120 for securing auxiliary fan 120. For example, the
complementary mating features 190 may be curved or arcuate members
that engage fan perimeter 180 to secure auxiliary fan 120 in place.
As used herein, terms of approximation, such as "approximately,"
"substantially," or "about," refer to being within a ten percent
margin of error.
[0060] Notably, complementary mating features 190 may also be sized
for securing the axial position of his auxiliary fan 120 within fan
duct 102. In this regard, for example, auxiliary fan 120 defines a
flange gap 192 between upstream flange 182 and downstream flange
184 along the axial direction A. Complementary mating features 190
are positioned within flange gap 192 to prevent auxiliary fan 120
from moving axially. More specifically, for example, flange gap 192
may define a gap width 194 along the axial direction A that is
substantially the same as the feature width 196 defined by the
complementary mating feature 190 along the axial direction A.
Although four complementary mating features 190 are illustrated as
positioned on each side of a rectangular isolation member 160, it
should be appreciated that any suitable number, size, and position
of mating features may be used according to alternative
embodiments.
[0061] Although auxiliary fan 120 is illustrated above as being
directly mounted within fan duct 102, it should be appreciated that
according to alternative embodiments, fan assembly 100 could
instead include a fan mounting structure that is separately
assembled and attached to fan duct 102. In this manner, according
to alternative embodiments, auxiliary fan 120 may be inserted into
isolation member 160 and then installed onto the fan mounting
structure. The fan mounting structure could then be separately
installed onto a fan duct before mounting to bulkhead 46. Other
configurations and constructions are possible and within the scope
of the present subject matter.
[0062] In sum, isolation member 160 and the fan installation method
and configuration described above can isolate auxiliary fan 120
from fan duct 102 and reduce noise generated by auxiliary fan 120
while providing make-up air. In this regard, by positioning an
elastomeric or rubber material between auxiliary fan 120 and fan
duct 102 (or any other suitable fan mounting structure), vibrations
transferred to fan duct 102 may be reduced significantly. Isolation
member 160 may be formed in a band around fan perimeter 180 of
auxiliary fan 120 and may include various protrusions or other
features, e.g., mating features 190, for locating and securing
auxiliary fan 120 in position within fan duct 102. In addition,
isolation member 160 may define one or more isolation flanges 170
that may be secured to fan duct 102 during assembly, thereby fixing
isolation member 160 and auxiliary fan 120 relative to fan duct
102.
[0063] Isolation member 160 thus provides a unique means of
locating and retaining an auxiliary fan within a fan duct while
isolating or damping vibrations generated during fan operation.
Isolating the fan as a noise source will reduce or eliminate noise
which may be a nuisance to occupants of the conditioned room and
otherwise result in a more desirable consumer experience. Other
configurations of fan duct 102 and isolation member 160, as well as
associated benefits and advantages of such constructions, will be
apparent to those having skill in the art.
[0064] Referring now to FIG. 14, auxiliary fan 120 will be
described according to an exemplary embodiment of the present
subject matter. It should be appreciated that the auxiliary fan 120
illustrated in FIG. 14 and described herein is only one exemplary
configuration of auxiliary fan 120. As illustrated, auxiliary fan
120 defines an axial direction A, a radial direction R, and a
circumferential direction C. Auxiliary fan 120 includes a plurality
of fan blades 210 that generally extend between a root 212 and a
tip 214. According to the illustrated embodiment, fan blades 210
includes seven blades positioned equidistantly about the
circumferential direction C. Fan blades 210 are sized, spaced, and
define a twist or camber that allow fan blades 210 to block a
substantial portion of noise trying to pass through auxiliary fan
120, e.g., when auxiliary fan 120 is off. However, it should be
appreciated that according to alternative embodiments, any suitable
number, size, and geometry of fan blades 210 may be used.
[0065] In addition, auxiliary fan 120 includes a stabilizer ring
216 that extends about the circumferential direction C to couple
fan blades 210. Stabilizer ring 216 is a generally rigid circular
member configured to provide rigidity between fan blades 210 to
prevent "growl" or "flutter" of fan blades 210, particularly during
transient operation when the speed of auxiliary fan 120 changing.
Stabilizer ring 216 is preferably positioned proximate tips 214 of
fan blades 210, where blade distortion or flutter might be most
extreme.
[0066] More specifically, according to the illustrated embodiment,
fan blades define a root diameter 220 and a tip diameter 222. In
addition, stabilizer ring 216 defines a ring diameter 224.
According to an exemplary embodiment, ring diameter 224 is between
about 50% greater than a root diameter 220 and 10% less than tip
diameter 222. According to still another embodiment, ring diameter
224 is substantially the same as tip diameter 222. In addition,
stabilizer ring 216 may be positioned only at a forward most end of
blades 210 along the axial direction A, the aft most end of blades
210 along the axial direction A, or at both. Moreover, according to
the illustrated embodiment, blades 210 may define a blade depth
along the axial direction A and the stabilizer ring 216 may extend
substantially along the entire blade depth of fan blades 210.
[0067] Referring now to FIGS. 15 through 17, fan assembly 100
further includes an electronics assembly 240 which is generally
configured for housing electronic components used for driving
auxiliary fan 120, vent door 82, or any other components of air
conditioner unit 10. In general, electronics assembly 240 includes
an electronics enclosure 242 that is mounted to fan duct 102 and
generally defines an electronics compartment 244 that is used for
housing electronic components. For example, according to exemplary
embodiments, controller 64 (or any other suitable control
electronics) may be housed within electronics enclosure 242, such
that auxiliary fan 120 may be controlled by controller 64. In
addition, an inverter or other power electronics may be stored
within electronics enclosure 242 to convert or rectify an input
power to a pulse with modulated (PWM) signal as needed for driving
auxiliary fan 120.
[0068] More specifically, electronics enclosure 242 may be a five
sided box defining an opening 246 through which electronic
components may be inserted into electronics compartment 244.
Electronics assembly 240 may further include a top plate 248 that
is attachable over opening 246 of electronics enclosure 242 to
substantially enclose electronics compartment 244. Inverter or
other power electronics may be attached directly to top plate 248
so that they are contained within electronics compartment 244.
[0069] In order to seal electronics enclosure 242 from the outside
elements and safely contain all electronic components within
electronics compartment 244, electronics assembly 240 may further
include a seal 250 positioned between electronics enclosure 242 and
top plate 248. For example, seal 250 may be an O-ring formed from
an elastomeric or rubber material such that it is resilient and is
compressed when top plate 248 is attached to electronics enclosure
242. In this regard, for example, top plate 248 may be mounted to
electronics enclosure 242 using one or more mechanical fasteners
252. In addition, it should be appreciated that top plate 248
defines a footprint that is larger than an outer flange 260 of
electronics enclosure 242. In this manner, positioning top plate
248 over opening 246 substantially seals opening 246 and forms a
single, enclosed electronics compartment 244.
[0070] In addition, as best illustrated in FIG. 16, electronics
enclosure 242, or more specifically outer flange 260, defines a
perimeter groove 262 that extends around a perimeter of electronics
enclosure 242 and is configured for receiving seal 250. Moreover,
electronics enclosure 242 may define a wire recess 264, e.g.,
through which wires are routed via a grommet to auxiliary fan 120.
Wire recess 264 may also define a recess groove 266 for partially
receiving seal 250. In this manner, seal 250 has a single,
continuous grooved pathway defined around all mating surfaces
between electronics enclosure 242, top plate 248, and grommet (not
shown).
[0071] According to an exemplary embodiment, top plate 248 is
formed to be a thermally conductive member for allowing heat to
escape electronics compartment 244. In this regard, for example,
top plate 248 may define or include a heat sink 270. In addition,
top plate 248 may be constructed of a thermally conductive
material, such as aluminum. By contrast, electronics enclosure 242
may be formed from a thermoset plastic or any other suitable
material. According still another embodiment, electronics enclosure
242 may also be formed from a thermally conductive material, such
as metal or aluminum.
[0072] As best illustrated in FIGS. 11, 12, 16, and 17, fan
assembly 100 may further define features for simplifying the
assembly of electronics enclosure 242 to fan duct 102. In this
regard, fan duct 102 may define one or more mounting pads 280 that
protrude from fan duct 102 and electronics enclosure 242 may define
one or more mounting recess 282. As used herein, "mounting pads"
are features that are configured for receipt within "mounting
recesses" to align and mount electronics enclosure 242 to fan duct
102. It should be appreciated that although fan duct 102 is
illustrated as defining mounting pads 280 and electronics enclosure
242 is illustrated as defining recesses 282, the two features could
be swapped. In this regard, electronics enclosure 242 could instead
define mounting pads 280 and fan duct 102 could instead define
recesses 282. Other configurations are possible and within scope of
the present subject matter.
[0073] Moreover, according to an exemplary embodiment, mounting
pads 280 and mounting recesses 282 are configured for receiving an
adhesive for joining electronics enclosure 242 and fan duct 102.
These features may further define profiles simplify the alignment
assembly of electronics enclosure 242 and fan duct 102. For
example, according to the illustrated embodiment upper portion 140
of fan duct 102 defines two L-shaped mounting pads 280 that are
configured for engaging a bottom 284 and a back 286 of electronics
enclosure 242. In this manner, assembly of fan assembly 100 is
simplified because a technician can easily align electronics
enclosure 242 onto fan duct 102 by sliding it along the L-shaped
mounting pads 280 until they contact back 286. In addition, upper
portion 140 also defines a lateral mounting pad 280 that is
configured to engage outer flange 260 of electronics enclosure 242.
In sum, these features simplify the alignment and positioning of
fan duct 102 and electronics enclosure 242 as well as the assembly
and installation of fan assembly 100.
[0074] Thus, electronics assembly 240 and electronics enclosure 242
described herein are capable of housing electronics components
safely and securely within an outdoor environment. Top plate 248 of
electronics enclosure 242 includes heat sink 270 having a larger
footprint than electronics enclosure 242 to prevent fluid entry
through opening 246. In addition, extruded O-ring seal 250 is
positioned within a groove 262 formed within outer flange 260 of
electronics enclosure 242 such that securing top plate 248 to
electronics enclosure 242 compresses the O-ring and seals
electronics compartment 244.
[0075] Moreover, fan duct 102 and electronics enclosure 242 are
permanently adhered together using an adhesive. More specifically,
mounting pads 280 and complementary recesses 282 may be defined on
fan duct 102 and electronics enclosure 242. These mounting pads 280
and recesses 282 interact or engage each other to provide adhesive
locations for permanently attaching fan duct 102 to electronics
enclosure 242. Fan duct 102 and electronics enclosure 242 may be
assembled prior to final installation into air conditioner unit 10,
thereby making the integration of the make-up air features less
labor intensive and easier to service.
[0076] As described above, fan assembly 100 includes fan duct 102
which is molded as two pieces that are joined together using an
adhesive, thereby simplifying tooling and ensuring easy assembly.
In addition, each piece may be compression molded from a thermoset
material or another flame resistant material, allowing for simple
mold tooling and part formation. The thermoset materials and
adhesive used to join the two pieces exhibit inherent flame
retardant properties, which is particularly important because fan
duct 102 is positioned in a region where flame propagation is a
concern.
[0077] Moreover, forming fan duct 102 as described herein allows
fan duct 102 to have unique shapes and geometry for reducing the
propagation of noise through fan duct 102 and vent aperture 80. In
this regard, for example, fan duct 102 has an asymmetrical or
offset arrangement along the transverse direction T, e.g., such
that there is no direct line of sight between inlet 106 and outlet
108 along the transverse direction T. Moreover, fan duct 102 may
protrude rearward, e.g., past outdoor fan shroud 36 and proximate
rear grill 22, such that inlet 106 is positioned in a region where
effects of the negative pressures developed by outdoor fan 32 may
be reduced or avoided.
[0078] In addition, a unique construction of auxiliary fan 120 is
provided which may reduce noise generated by auxiliary fan 120. For
example, conventional axial fans generated blade "growl" or
fluttering, particularly when the fan is shut off or changes
speeds. This noise may have a tendency to propagate through fan
duct 102, producing unacceptable noise within the room or indoor
portion 12. However, auxiliary fan 120 described above may include
more blades 210, a stabilizer ring 216, and blade geometries that
results in a significantly quieter operation. For example, the rate
of change of rotational speed of auxiliary fan 120 is lower due to
higher inertia, the increased number of blades and their geometry
deflect outside to inside noise transmission, etc. The fan
construction, duct construction, and other noise isolating features
provide an acoustic advantage to air conditioner unit 10 described
herein.
[0079] In this manner, air conditioner unit 10 includes fan
assembly 100 which has fan duct 102 and auxiliary fan 120 that
provide the appropriate amount of make-up air to meet government
regulations and building codes, keeps the noise created by fan
assembly 100 to a minimum, and maintains guest comfort and
satisfaction at a maximum. In addition, the manufacturing,
assembly, and installation of fan assembly 100 are simplified,
tooling costs are reduced, and the reliability and performance of
air conditioner unit 10 is improved. Other advantages and benefits
will be apparent to those having skill in the art.
[0080] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to practice the invention, including making and
using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they include structural elements that do not
differ from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal languages of the claims.
* * * * *