AIR HANDLER BLOWER AND METHOD OF OERATING THE SAME

TECHNICAL FIELD

The disclosed devices and methods relate generally to an air handler blower and a method of operating the same. More particularly, the disclosed devices and methods relate to an air handler blower that can equalize air flow on both a side accommodating a motor and a side not accommodating a motor.

BACKGROUND

A heating, ventilation, and air conditioning (HVAC) system operates by drawing input air in from an area to be heated or cooled, conditioning the air (i.e., heating or cooling it), and blowing the conditioned output air back into the area to be heated or cooled. In many systems an air handler blower is used to draw in the input air. Such an air handler blower includes a hollow cylindrical blower wheel made up of multiple blades arranged around the periphery of the cylinder. A motor rotates the blower wheel so that air is drawn through openings on the circular ends of the blower wheel into the blower wheel's hollow center. The air is then blown out the sides of the blower wheel by the blades as the blower wheel rotates. This air is then directed as needed for conditioning.

For structural reasons, a center plate can be formed inside the hollow center of the blower wheel. The center plate is a structural element that bisects the hollow center into first and second hollow portions. The first hollow portion (or first cavity) has air drawn in from an opening on a first side of the blower wheel, and second hollow portion (or second cavity) has air drawn in from an opening on a second side of the blower wheel. A first portion of the blades adjacent to the first hollow portion draws air from the first hollow portion and blows it out along the side of the blower wheel; and a second portion of the blades adjacent to the second hollow portion draws air from the second hollow portion and blows it out along the side of the blower wheel. The center plate provides an element that intersects a center line of the blower wheel and allows the motor to more easily rotate the blower wheel.

In order to keep the air handler blower compact, the motor that rotates the blower wheel is often arranged proximate to one side of the blower wheel. In many air handler blowers this means that the motor will partially obscure either the opening into the first hollow portion or the opening into the second hollow portioning. Because of this obstruction in one of the openings, the flow of air into the hollow portion whose opening is obscured may be restricted. This can lead to less air passing through that hollow portion of the blower wheel, thereby restricting the air passing through the entire air handler blower and reducing the operating efficiency of the air handler blower.

It would therefore be desirable to provide an air handler blower that can equalize air flow between two sides of a bisected blower wheel, regardless of how the air handler blower is arranged.

SUMMARY OF THE INVENTION

According to one or more embodiments, an air handler blower is provided, comprising: a blower wheel having a center plate having one or more center openings, a first cylindrical blade assembly extending from a first side of the center plate, the first cylindrical blade assembly containing a plurality of first blades extending from the first side of the center plate and arranged in a circle to define a first cavity, the plurality of first blades each attached by a first end to the first side of the center plate, and a second cylindrical blade assembly extending from a second side of the center plate opposite the first side, the second cylindrical blade assembly containing a plurality of second blades extending from the second side of the center plate and arranged in a circle to define a second cavity, the plurality of second blades each attached by a first end to the second side of the center plate; a motor located proximate to the first cylindrical blade assembly and configured to rotate the blower wheel; and an axle connecting the motor and the center plate.

The first cylindrical blade assembly may further include a first circular blower wheel rim attached to respective second ends of each of the plurality of first blades and defining a second blower opening, and the second cylindrical blade assembly may further include a second circular blower wheel rim attached to respective second ends of each of the plurality of second blades and defining a second blower opening.

The first blade cylinder may have a first width extending from the first side of the center plate, the second blade cylinder may have a second width extending from the second side of the center plate, and the first width may be substantially equal to the second width.

The air handler blower may further comprise a connector configured to secure the axle to the center plate, wherein the center plate includes an axle hole configured to accommodate the axle.

The plurality of first blades may be arranged such that the first cylindrical blade assembly will draw first intake air into the first cavity and generate first exhaust air at an outer circumference of the first cylindrical blade assembly when the blower wheel is rotated, and the plurality of second blades may be arranged such that the second cylindrical blade assembly will draw second intake air into the second cavity and generate second exhaust air at an outer circumference of the second cylindrical blade assembly when the blower wheel is rotated.

The motor partly may obscure the first blower opening.

The center plate may further include one or more air movers configured to draw air from the second cavity into the first cavity.

The air movers may include one of an air scoop, a louver, a fixed blade, or an adjustable blade.

The air movers may protrude into the second cavity; or the air movers may protrude into the first cavity.

The center plate may further include one or more third blades configured to draw air from the second cavity into the first cavity, each of the one or more third blades being associated with a corresponding one of the center openings, and the one or more third blades may be noncoplanar with respect to the center plate.

Each of the center openings may have a corresponding inner circumference, each of the one or more third blades may have a substantially same shape as a corresponding one of the center openings, and each of the one or more third blades may be connected to a portion of the circumference of a corresponding one of the center openings.

The openings may be substantially triangular; or the openings may be substantially circular.

The center plate may further include an outer plate having an inner opening with a first circumference, an inner plate having a second circumference formed in the inner opening, and a plurality of spokes connecting the outer plate to the inner plate, wherein the second circumference is smaller than the first circumference, and the one or more openings include a main opening between the first circumference and the second circumference.

The air handler blower may further comprise an outer casing surrounding the blower wheel and containing an exhaust opening, the outer casing being configured to combine the first and second exhaust air into combined exhaust air and to expel the combined exhaust air through the exhaust opening.

A heating, ventilation and air-conditioning device may also be provided comprising the air handler blower described above, and an air-conditioner configured to condition the combined exhaust air.

The heating, ventilation and air-conditioning device may further comprise an outer casing surrounding the air handler blower, the outer casing having an intake opening configured to draw in outside air, wherein the intake opening is located adjacent to a side of the blower wheel.

The heating, ventilation and air-conditioning device may further comprise an outer casing surrounding the air handler blower, the outer casing having a first intake opening configured to draw in first outside air and a second intake opening configured to draw in second outside air, wherein the first intake opening is located adjacent to the first cavity, and wherein the second intake opening is located adjacent to the second cavity.

An air handler blower is provided, comprising: a blower wheel having a center plate having one or more center openings, and one or more air movement mechanisms configured to draw air from the second cavity into the first cavity, a first cylindrical blade assembly extending from a first side of the center plate, the first cylindrical blade assembly containing a plurality of first blades extending from the first side of the center plate and arranged in a circle to define a first cavity, the plurality of first blades each attached by a first end to the first side of the center plate, and a second cylindrical blade assembly extending from a second side of the center plate opposite the first side, the second cylindrical blade assembly containing a plurality of second blades extending from the second side of the center plate and arranged in a circle to define a second cavity, the plurality of second blades each attached by a first end to the second side of the center plate; a motor located proximate to the first cylindrical blade assembly and configured to rotate the blower wheel; and an axle connecting the motor and the center plate.

The air movement mechanisms may include one of an air scoop, a louver, a fixed blade, or an adjustable blade.

The air movement mechanisms may protrude into the second cavity; or the air movement mechanisms may protrude into the first cavity.

The air movement mechanisms may include one or more third blades configured to draw air from the second cavity into the first cavity, each of the one or more third blades being associated with a corresponding one of the center openings, the one or more third blades may be noncoplanar with respect to the center plate.

A method is provided of operating an air handler blower having a blower wheel with a center plate a first cylindrical blade assembly attached to a first side of the center plate, and a second cylindrical blade assembly attached to a first side of the center plate, comprising: rotating the blower wheel; drawing first intake air into a first cavity defined by the first cylindrical blade assembly at a first air pressure; drawing second intake air into a second cavity defined by the second cylindrical blade assembly at a second air pressure greater than the first air pressure; passing a portion of the second intake air from the second cavity to the first cavity through openings in the center plate to create second reduced intake air in the second cavity and first increased intake air in the first cavity; moving the first increased intake air from the first cavity to an outer circumference of the first cylindrical blade assembly as first exhaust air; moving the second decreased intake air from the second cavity to an outer circumference of the second cylindrical blade assembly as second exhaust air; and combining the first exhaust air and the second exhaust air to form combined exhaust air.

The passing of the portion of the second intake air from the first cavity to the second cavity through openings in the center plate may be performed at least in part by equalizing the first pressure and the second pressure.

The passing of the portion of the second intake air from the first cavity to the second cavity through openings in the center plate may be performed at least in part by forcing a portion of the second intake air from the second cavity into the first cavity using one or more air movers attached to the center plate.

The air movers may include one of an air scoop, a louver, a fixed blade, or an adjustable blade.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying figures, where like reference numerals refer to identical or functionally similar elements and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate an exemplary embodiment and to explain various principles and advantages in accordance with the present disclosure.

FIG. 1 is a diagram of an air handler blower from a first side according to disclosed embodiments;

FIG. 2 is a diagram of the air handler blower of FIG. 1 from a second side opposite the first side according to disclosed embodiments;

FIG. 3 is a cross-sectional view of an air handler blower in an air handler with a single bottom air intake opening according to disclosed embodiments;

FIG. 4 is a cross-sectional view of the air handler blower of FIG. 3 along line IV-IV′ according to disclosed embodiments;

FIG. 5 is a cross-sectional view of the air handler blower of FIG. 3 along line V-V′ according to disclosed embodiments;

FIG. 6 is a perspective view of the blower wheel of the air handler blower of FIG. 3 according to disclosed embodiments;

FIG. 7 is a cross-sectional view of an air handler blower in an air handler with two side air intake openings according to disclosed embodiments;

FIG. 8 is a plan view of a center plate in a blower wheel having multiple triangular openings according to disclosed embodiments;

FIG. 9 is a side view of the center plate of FIG. 8 along the line IX-IX′ according to disclosed embodiments;

FIG. 10 is a plan view of a center plate in a blower wheel having multiple circular openings according to disclosed embodiments;

FIG. 11 is a plan view of a center plate structure in a blower wheel having first and second center plates connected by spokes according to disclosed embodiments.

FIG. 12 is a plan view of a center plate in a blower wheel having multiple triangular openings and blades formed adjacent to each opening according to disclosed embodiments;

FIG. 13 is a side view of the center plate of FIG. 12 along line XII-XII′ in which the blades are each arranged to push air through an associated center opening when the center plate rotates according to disclosed embodiments;

FIG. 14 is a side view of the center plate of FIG. 12 along line XII-XII′ in which the blades are arranged to create an area of increased negative air pressure what will draw air through an associated center opening when the center plate rotates according to disclosed embodiments; and

FIG. 15 is a flow chart showing the operation of an air handler blower according to disclosed embodiments.

DETAILED DESCRIPTION
Introduction

In overview, the present disclosure concerns an air handler blower with a cylindrical blower wheel that draws in input air through two sides and blows the input air as output air through blades on the sides of the blower wheel. A motor that operates to rotate the blower wheel is arranged such that it partially obscures one side of the blower wheel.

The blower wheel includes a hollow portion defined by a series of blades arranged in a circle. The hollow portion is bisected by a center plate that is attached to the motor by an axle and is used to rotate the blower wheel. The center plate divides the hollow portion into a first cavity on the side with the motor and a second cavity on the side without the motor. The center plate has at least one opening in it to allow air to pass between the first and second cavities. The one or more openings may also include air movement mechanisms (air movers) that assist in the movement of air between the first and second cavities.

More particularly, various inventive concepts and principles are embodiments in systems, devices, and methods therein which provide an air handler blower that solves a problem of unequal air flows between the two sides of the blower wheel. Furthermore, the disclosed air handler blower will equalize air flow between the two sides of the blower wheel in a variety of configurations and placements of the air handler blower.

The instant disclosure is provided to further explain in an enabling fashion the best modes of performing one or more embodiments. The disclosure is further offered to enhance an understanding and appreciation for the inventive principles and advantages thereof, rather than to limit in any manner the embodiments.

It is further understood that the use of relational terms, such as first and second, if any, are used to distinguish one from another entity, item, or action without necessarily requiring or implying any actual such relationship or order between such entities, items or actions. Some embodiments may include a plurality of processes or steps, which can be performed in any order unless expressly and necessarily limited to a particular order (i.e., processes or steps that are not so limited may be performed in any order).

As further discussed below, various inventive principles and combinations thereof are advantageously employed to provide an air handler blower which is adapted for mounting to an air handler such as a furnace or an air-conditioner.

Air Handler Blower

FIG. 1 is a diagram of an air handler blower 100 from a first side according to disclosed embodiments. FIG. 2 is a diagram of the air handler blower 100 of FIG. 1 from a second side opposite the first side according to disclosed embodiments.

As shown in FIGS. 1 and 2, the air handler blower 100 includes an outer casing 110, a blower wheel 120, a first blower intake opening 130, a second blower intake opening 135, a motor 140, an axle 150, an exhaust opening 160, and a securing mechanism 170.

The outer casing 110 is a structure formed around the blower wheel 120 that serves to protect the blower wheel 120 and to restrict the movement of air that is circulated by the air handler blower 100. In various embodiments the outer casing 110 can be made of metal, plastic, or any similar suitable material.

The blower wheel 120 is a cylindrical structure formed of a plurality of blades arranged in a circle to create a hollow portion between the blades. The blades are arranged such that there is space in between each blade and that when the blower wheel 120 is rotated along its center axis, the blades will draw air from the hollow portion and expel it out the sides of the blower wheel 120.

Although not shown, the blower wheel 120 may have a center plate that separates the hollow portion between the blades into a first cavity and a second cavity. The center plate passes through the center axis of the blower wheel 120. In some embodiments, the center plate is located in the middle of the blower wheel 120, bisecting the hollow portion between the blades equally into a first cavity and a second cavity. In other embodiments, the center plate is located closer to one and of the blower wheel 120, such that the first cavity and the second cavity are unequal in size.

In some embodiments, the blades that make up the blower wheel 120 may be single blades that extend from one end of the blower wheel 120 to the other. In other embodiments, the blades may be a series of smaller blades that each extend from the center plate to either end of the blower wheel 120. Other configurations are possible that provide a plurality of blades to draw air out of the first and second cavities to the periphery of the blower wheel 120.

The first blower intake opening 130 is located on a first side of the blower wheel 120 and opens into the first cavity between the blades in the blower wheel 120. The first blower intake opening 130 is provided such that when the blower wheel 120 is rotating, the movement of air from the first cavity through the blades to the periphery of the blower wheel 120 will draw air into the first cavity through the first blower intake opening 130.

The second blower intake opening 135 is located on a second side of the blower wheel 120 opposite the first side and opens into the second cavity between the blades in the blower wheel 120. The second blower intake opening 135 is provided such that when the blower wheel 120 is rotating, the movement of air from the second cavity through the blades to the periphery of the blower wheel 120 will draw air into the second cavity through the second blower intake opening 135.

The motor 140 operates to rotate the axle 150, which is connected to the blower wheel 120, and thereby rotate the blower wheel 120. The motor 140 is located partially in the first blower intake opening 130 such that it partially obscures the first blower intake opening 130. Air being drawn into the first cavity must pass by the motor 140. As a result, the passage of air through the first blower intake opening 130 into the first cavity will be restricted compared to the passage of air through the second blower intake opening 135 into the second cavity.

The axle 150 is connected between the motor 140 and the center plate (not shown) of the blower wheel 120. The motor 140 operates to rotate the axle 150 and thereby rotate the blower wheel 120. The axle 150 extends along the centerline of the blower wheel 120 between the motor 140 and the center plate and is connected to the middle of the center plate. Thus, when the axle 150 is rotated by the motor 140 it causes the center plate to rotate and with it the entire blower wheel 120.

The exhaust opening 160 is an opening in the outer casing 110 that is used to direct the air blown by the blower wheel 120. Specifically, as air is drawn into the first and second cavities in the blower wheel 120 through the first and second blower intake openings 130, 135, through the blades, and out to a periphery of the blower wheel 120, the air will be directed by the outer casing 110 such that it is a blown out the exhaust opening 160. The exhaust opening 160 can then be connected to a portion of the air handler which is intended to receive and process air to be conditioned.

The securing mechanism 170 is a part of the air handler blower 100 that allows the air handler blower 100 to be secured to another part of an air handler. In the embodiment of FIGS. 1 and 2, the securing mechanism 170 is shown as being two legs connected to a bottom portion of the outer casing 110. However, this is by way of example only. Alternate embodiments can include any suitable securing mechanism to secure the air handler blower 100 to another part of the air handler. Such variation may be necessary in different embodiments as different air handlers may position the air handler blower 100 in different places and configurations.

FIG. 3 is a cross-sectional view of an air handler blower 301 in an air handler 300 with a single bottom air intake opening 308 according to disclosed embodiments. As shown in FIG. 3, air handler 300 includes the air handler blower 301, an air intake chamber 303, and an outflow chamber 306. The air handler blower 301 includes an exhaust vent 310, a blower wheel 120, a motor 140, an axle 150, and an axle securing mechanism (i.e., a connector) 339. The blower wheel 120 includes a first blower side 320, a second blower side 325, and a center plate 330. The first blower side 320 includes a plurality of first blower blades 340 and a first blower wheel rim 350. The second blower side 325 includes a plurality of second blower blades 345 and a second blower wheel rim 355. The center plate 330 includes an axle hole 333 and one or more center openings 336.

The air handler blower 301 operates in a manner similar to the air handler blower 100 from FIGS. 1 and 2. Specifically, it operates to draw air into the first and second cavities 360, 365 through openings defined by the first and second blower wheel rims 350, 355, respectively by rotating the blower wheel 120. The air drawn in to the first and second cavities 360, 365 will then be blown out between gaps in the first and second blower blades 340, 345 to a periphery of the blower wheel 120.

The air intake chamber 303 is a portion of the air handler 300 that surrounds the air handler blower 301. The air intake chamber 303 protects the air handler blower 301 and focuses where input air is drawn in from a room to be heated or cooled into the air handler blower 301. In the embodiment of FIG. 3, the air intake chamber 303 includes a casing intake opening 308 on the bottom below the air handler blower 301. The casing intake opening 308 limits how main intake air 370 can enter the air intake chamber 303 and thus be provided to the air handler blower 301. However, this is by way of example only. Alternate embodiments can place one or more casing intake openings along the air intake chamber 303 wherever is desired. Alternate embodiments could even omit the air intake chamber 303 entirely and leave the air handler blower 301 open to room that is to be heated or cooled.

The air outflow chamber 306 is connected to the air handler blower 301 at the exhaust vent 310 and provides a pathway for exhaust air 390, 395 blown by the air handler blower 301 to progress to the remainder of the air handler 300, e.g., a furnace or air-conditioner.

The exhaust vent 310 is connected between the blower wheel 120 and the air outflow chamber 306. In various embodiments the exhaust vent 310 can be a part of an outer casing 110. As air is blown out of the blower wheel 120 at the periphery of the blower wheel 120, it is channeled by the exhaust vent 310 into the outflow chamber 306. Although not shown explicitly in FIG. 3, an outer casing may be provided around the air handler blower 301 that channels the air blown out at the periphery of the blower wheel 120.

The motor 140 and the axle 150 operate as described above with respect to FIGS. 1 and 2. Specifically, the motor 140 operates to rotate the axle 150, and the axle 150 operates to rotate the blower wheel 120. The axle 150 is connected to the center plate 330 via the axle hole 333 and the axle securing mechanism 339 such that when the axle 150 rotates the center plate 330 rotates and with it the entire blower wheel 120.

The blower wheel 120 is rotated by the motor 140 via the axle 150. As it rotates, the blower wheel 120 draws first and second side intake air 373, 376 into the first and second cavities 360, 365, respectively, and blows air out at the periphery of the blower wheel 120.

As noted above, in the embodiment of FIG. 3, the blower wheel 120 includes a first blower side 320 that defines the first cavity 360 and a second blower side 325 that defines the second cavity 365. Each of the first and second blower sides 320, 325 includes its own set of blower blades 340, 345. This is only by way of example, however. Alternate embodiments could use a single set of blower blades that extend across the sides of both the first and second cavities 360, 365.

The plurality of first blower blades 340 are arranged in a circle around the periphery of the center plate 330. They are each attached at a first end to a first side of the center plate 330 and extend away from the center plate 330 in a first direction. The plurality of first blower blades 340 define the first cavity 360.

The first blower wheel rim 350 is formed in a generally circular shape and is attached to a second end of each of the plurality of first blower blades 340. The first blower wheel rim 350 defines an opening that allows first side intake air 373 into the first cavity 360. Although the first blower wheel rim 350 is provided in the embodiment of FIG. 3 to add stability to the first blower side 320 of the blower wheel 120, alternate embodiments could omit this element.

Each of the plurality of first blower blades 340 is placed such that there is space between adjacent blades through which air can flow. The orientation of the plurality of first blower blades 340 is such that when the blower wheel 120 is rotated by the motor 140, the plurality of first blower blades 340 will draw air from the first cavity 360 and expel the air from the first cavity 360 to an area on the periphery of the first blower side 320 outside of the circle of the plurality of first blower blades 340. As the air is drawn from the first cavity 360 to the periphery of the first blower side 320, this will reduce the pressure inside the first cavity 360 and draw the first side intake air 373 into the first cavity 360 from the intake chamber 303.

The plurality of second blower blades 345 are arranged in a circle around the periphery of the center plate 330. They are each attached at a first end to a second side of the center plate 330 opposite the first side and extend away from the center plate 330 in a second direction opposite the first direction. The plurality of second blower blades 345 define the second cavity 365.

The second blower wheel rim 355 is formed in a generally circular shape and is attached to a second end of each of the plurality of second blower blades 345. The second blower wheel rim 355 defines an opening that allows second side intake air 376 into the second cavity 365. Although the second blower wheel rim 355 is provided in the embodiment of FIG. 3 to add stability to the second blower side 325 of the blower wheel 120, alternate embodiments could omit this element.

Each of the plurality of second blower blades 345 is placed such that there is space between adjacent blades through which air can flow. The orientation of the plurality of second blower blades 345 is such that when the blower wheel 120 is rotated by the motor 140, the plurality of second blower blades 345 will draw air from the second cavity 365 and expel the air from the second cavity 365 to an area on the periphery of the second blower side 325 outside of the circle of the plurality of second blower blades 345. As the air is drawn from the second cavity 365 to the periphery of the second blower side 325, this will reduce the pressure inside the second cavity 365 and draw the second side intake air 376 into the second cavity 365 from the intake chamber 303.

As shown in FIG. 3, the motor 140 in this disclosed embodiment is arranged proximate to the opening into the first cavity 360. In fact, in this disclosed embodiment the motor 140 is arranged to extend partially into the first cavity 360. Because the motor 140 obscures the entrance to the first cavity 360 and nothing obscures the entrance to the second cavity 365, the first side intake air 373 flowing into the first cavity 360 will have a lower air flow than the second side intake air 376 flowing into the second cavity 365.

The center plate 330 is a circular plate located between the first cavity 360 and the second cavity 365 and connected to the first and second blower blades 340, 345. It can be generally flat or may have portions that are not coplanar. For example, the center plate 330 may have a portion that extends farther into the first cavity 360 or the second cavity 365. In the embodiment of FIG. 3, the center plate 330 is located generally in the middle of the blower wheel 120, roughly bisecting the blower wheel 120 such that the first blower side 320 and the second blower side 325 are approximately equal in size. However, this is by way of example only. Some embodiments could offset the center plate 330 in one direction or the other such that the sizes of the first and second blower sides 320, 325, and therefore the sizes of the first and second cavities 360, 365, vary.

In some alternate embodiments, the center plate 330 is arranged to make the first cavity 360 smaller than the second cavity 365. This can be done to account for the fact that the first side intake air 373 entering the first cavity 360 will have a smaller air flow than the second side intake air 376 entering the second cavity 365 because the motor 140 is arranged to obscure the opening into the first cavity 360.

The axle hole 333 is formed in the center plate 330 where the center plate 330 intersects the centerline of the blower wheel 120. The axle hole 333 is provided so that the axle 150 can pass through it from the first cavity 360 to the second cavity 365 and be secured by the axle securing mechanism 339 in the second cavity 365.

The axle securing mechanism 339 is a connector that is configured to secure the axle 150 to the center plate 330. The axle securing mechanism 339 can be formed on either the first or second side of the center plate 330 in various embodiments. In the embodiment of FIG. 3, axle securing mechanism 339 is formed on the second side of the center plate 330, opposite the first side that faces the motor 140. However, this is by way of example only.

In alternate embodiments the axle hole 333 can be omitted and the axle securing mechanism 339 can be configured to attach the axle 150 to the center plate 330 without the axle 150 passing through the center plate 330.

The center openings 336 are provided in the center plate 330 as conduits for air to pass from the first cavity 360 to the second cavity 365 or vice versa. These center openings 336 can vary in shape and configuration in different embodiments. In the embodiment of FIG. 3, the center openings 336 are triangular. However, this is by way of example only.

Although not shown in FIG. 3, one or more of the center openings 336 can have an air mover associated with them. An air mover is a device that assists air in passing either from the first cavity 360 to the second cavity 365 or vice versa. Examples of air movers include air scoops, louvers, fixed blades, or adjustable blades. These air movers may protrude into one or both of the first and second cavities 360, 365 and are configured to assist in the moving of the air between the first and second cavities 360, 365 when the blower wheel 120 is in motion. This assistance can be achieved by physical pressure against the air in one of the cavities 360, 365 (e.g., by a blade or air scoop pushing the air from one cavity to the other), the creation of a low-pressure zone that will draw air from one cavity to the other (e.g., by a blade that is placed to create a low-pressure zone), or by any mechanism that will assist in the movement of air.

The air movers can rely upon the rotation of the blower wheel 120 to function or could function independently of the rotation of the blower wheel 120. Other nonmechanical air movers can be used in different embodiments.

In operation, the motor 140 will rotate the axle 150, which in turn will rotate the center plate 330 to which it is attached. Since the center plate 330 is connected to the first and second blower blades 340, 345, this will cause the entire blower wheel 120 to rotate. As the blower wheel 120 rotates, the first blower blades 340 will draw air from the first cavity 360 and expel this air out along the periphery of the blower wheel 120. This expelled air will be directed by the exhaust vent 310 and will be provided as first exhaust air 390 into the outflow chamber 306. Likewise, the second blower blades 345 will draw air from the second cavity 365 and expel this air out along the periphery of the blower wheel 120. This expelled air will be directed by the exhaust vent 310 and will be provided as second exhaust air 395 into the outflow chamber 306.

As air is drawn out of the first cavity 360, this will cause first side intake air 373 to be drawn from the intake chamber 303 into the first cavity 360. Likewise, as air is drawn out of the second cavity 365, this will cause second side intake air 376 to be drawn from the intake chamber 303 into the second cavity 365. The movement of first and second side intake air 373, 376 from the intake chamber 303 to the first and second cavities, respectively, will further cause main intake air 370 to be drawn into the intake chamber 303 via the casing intake opening 308 at the bottom of the intake chamber 303. In this way, main intake air 370 will be drawn in from a room to be heated or cooled through the casing intake opening 308, and first and second exhaust air 390, 395 will be provided in the outflow chamber 306 to be forwarded to an air handler that will heat or cool the air and provide the treated air back to the room to be heated or cooled.

Because the motor 140 is located in a position that obscures the opening between the intake chamber 303 and the first cavity 360, the first side intake air 373 that enters the first cavity 360 will generally represent a lesser flow of air as compared to the second side intake air 376 that enters the second cavity 365. Without any accommodation, this would cause the first exhaust air 390 provided by the first blower side 320 of the blower wheel 120 to be reduced as compared to the second exhaust air 395 provided by the second blower side 325 of the blower wheel 120. This could cause an undesirable drop in the efficiency of the air handler blower 301.

The presence of the center openings 336 addresses this potential imbalance in the exhaust air 390, 395. Since the first side intake air 373 is smaller than the second side intake air 376, the air pressure in the first cavity 360 would generally be lower than the air pressure in the second cavity 365. In other words, the first cavity 360 will be essentially starved for air as compared to the second cavity 365. However, the imbalance in air pressures between the first and second cavities 360, 365 will cause transfer air 380 to pass from the second cavity 365 to the first cavity 360 through the one or more center openings 336 to equalize the pressure. By equalizing the air pressure between the first and second cavities 360, 365, the air handler blower can likewise equalize the first and second exhaust air 390, 395. This can keep the efficiency of the air handler blower 301 high.

Furthermore, if air movers are provided with respect to the center openings 336, the passage of air from the higher-pressure second cavity 365 to the lower-pressure first cavity 360 can the assisted. The air movers can effectively improve the speed at which the air pressures between the first and second cavities 360, 365 are equalized.

By equalizing the pressures between the first and second cavities 360, 365 the efficiency of the air handler blower 301 can be increased. This gain in efficiency can take the form of either allowing more air to be blown out as first and second exhaust air 390, 395 for the same power cost, or allowing the same amount of air to be blown out as first and second exhaust air 390, 395 at a lower power input.

FIG. 4 is a cross-sectional view of the air handler blower 301 of FIG. 3 along line IV-IV′ according to disclosed embodiments. As shown in FIG. 4, the blower wheel 120 is formed inside an outer casing 110. The blower wheel 120, and in particular the first blower wheel rim 350, define a first blower opening 410 that opens into the first cavity 360. The motor 140 is arranged such that it partially obscures the first blower opening 410. The securing mechanism 170 is arranged on a side of the outer casing 110 where it can secure the air handler blower 301 to the intake chamber 303. Line identifies the cross-section of FIG. 4 shown in FIG. 3.

As shown with respect to FIGS. 3 and 4, during operation, air is drawn into the first cavity 360 via the first blower opening 410. This air is then discharged from the first cavity 360 into the outer casing 110 by the first blower blades 340 in the blower wheel 120. The outer casing 110 directs the discharged air through the exhaust vent 310 and ultimately into the outflow chamber 306 as first exhaust air 390.

FIG. 5 is a cross-sectional view of the air handler blower 301 of FIG. 3 along line V-V′ according to disclosed embodiments. As shown in FIG. 5, the blower wheel 120 is formed inside an outer casing 110. Blower wheel 120, and in particular the second blower wheel rim 355, define a second blower opening 510 that opens into the second cavity 365. The securing mechanism 170 is arranged on a side of the outer casing 110 where it can secure the air handler blower 301 to the intake chamber 303. Line shows the cross-section shown by FIG. 3.

As shown with respect to FIGS. 3 and 5, during operation, air is drawn into the second cavity 365 the via the second blower opening 510. This air is then discharged from the second cavity 365 into the outer casing 110 by the second blower blades 345 in the blower wheel 120. The outer casing 110 directs the discharged air through the exhaust vent 310 and ultimately into the outflow chamber 306 as second exhaust air 395.

FIG. 6 is a perspective view of the blower wheel 120 of the air handler blower 301 of FIG. 3 according to disclosed embodiments. As shown in FIG. 6, the blower wheel 120 is separated into a first blower side 320 and a second blower side 325 by a center plate 330.

The first blower side 320 includes a first blower wheel rim 350 and a plurality of first blower blades 340 that extend between a first side of the center plate 330 and the first blower wheel rim 350. The first blower blades 340 are arranged in a circle to define the first cavity 360, with space in between the first blower blades 340 such that air can be expelled from the first cavity 360 to a periphery of the first blower side 320 when the blower wheel 120 is rotated. The first blower opening 410 is defined by the first blower wheel rim 350 and opens into the first cavity 360.

The second blower side 325 includes a second blower wheel rim 355 and a plurality of second blower blades 345 that extend between a second side of the center plate 330 and the second blower wheel rim 355. The second blower blades 345 are arranged in a circle to define the second cavity 365, with space in between the first blower blades 340 such that air can be expelled from the second cavity 365 to a periphery of the first blower side 320 when the blower wheel 120 is rotated. Although not explicitly shown in FIG. 6, the second blower opening 510 is defined by the second blower wheel rim 355 and opens into the second cavity 365.

FIG. 7 is a cross-sectional view of an air handler blower 301 in an air handler 700 with two side air intake openings 708, 709 according to disclosed embodiments. The air handler 700 of FIG. 7 is similar to the air handler 300 of FIG. 3 except that the air handler 700 of FIG. 7 has two side casing intake openings 708, 709, while the air handler 300 of FIG. 3 has a single bottom air intake opening 308.

As shown in FIG. 7, the air handler 700 includes the air handler blower 301, an air intake chamber 703, and an outflow chamber 306. The air handler blower 301 includes an exhaust vent 310, a blower wheel 120, a motor 140, an axle 150, and an axle securing mechanism (i.e., a connector) 339. The blower wheel 120 includes a first blower side 320, a second blower side 325, and a center plate 330. The first blower side 320 includes a plurality of first blower blades 340 and a first blower wheel rim 350. The second blower side 325 includes a plurality of second blower blades 345 and a second blower wheel rim 355. The center plate 330 includes an axle hole 333 and one or more center openings 336.

The air handler blower 301 operates as described above with respect to FIG. 3. Specifically, the air handler blower 301 operates to draw air into the first and second cavities 360, 365 through openings defined by the first and second blower wheel rims 350, 355, respectively by rotating the blower wheel 120. The air drawn in to the first and second cavities 360, 365 will then be blown out between gaps in the first and second blower blades 340, 345 to a periphery of the blower wheel 120.

Similar to the air intake chamber 303 in the air handler 300 of FIG. 3, the air intake chamber 703 of FIG. 7 is a portion of the air handler 700 that surrounds the air handler blower 301. The air intake chamber 703 protects the air handler blower 301 and focuses where input air is drawn in from a room to be heated or cooled into the air handler blower 301. However, in the embodiment of FIG. 7, the air intake chamber 703 includes two casing intake openings: a first casing intake opening 708 and a second casing intake opening 709. The first casing intake opening 708 is on a first side of the air intake chamber 703 opposite the first opening 410 into the first cavity 360; and the second casing intake opening 709 is on a second side of the air intake chamber 703 opposite the second opening 510 into the second cavity 365.

Thus, first main intake air 760 enters the air intake chamber 703 via the first casing intake opening 708 and second main intake air 770 enters the air intake chamber 703 via the second casing intake opening 709. Since nothing obscures the second opening 510 into the second cavity 365, the second main intake air 770 flows directly into the second cavity 365 unimpeded. However, since the motor 140 obscures the first opening 410 into the first cavity 360, the first main intake air 760 is restricted by the motor 140 into first restricted intake air 763. This first restricted intake air 763 has a lesser air flow than the second main intake air 770. As a result, the amount of air flowing into the first cavity 360 is less than the amount of air flowing into the second cavity 365.

As with the embodiment of FIG. 3, the embodiment of FIG. 7 uses the center openings 336 in the center plate 330 to allow transfer air 380 to move air from the second cavity 365 to the first cavity 360 in order to equalize the first and second exhaust air 390, 395. The embodiment of FIG. 7 discloses the center openings 336 without any additional air movers and relies upon the difference in air pressure between the first cavity 360 and the second cavity 365 to facilitate the movement of the transfer air 380. However, this is by way of example only. Alternate embodiments could employ air movers in association with one or more of the center openings 336. These air movers can include air scoops, louvers, fixed blades, adjustable blades, or any mechanism to move air between the first and second cavities 360, 365.

The use of a single casing intake opening on the bottom of the intake chamber 303 in the embodiment of FIG. 3 and the use of two casing intake openings 708, 709 opposite the first and second cavities 360, 365 of the blower wheel 120 on the sides of the intake chamber 703 in the embodiment of FIG. 7 are by way of example only. Alternate embodiments can vary the number of casing intake openings and vary their placement as desired. Alternate embodiments could even omit the air intake chamber 303 entirely and leave the air handler blower 301 open to the room.

Although the embodiments of FIG. 3 and FIG. 7 show the motor 140 being arranged opposite the first cavity 360 and obscuring air entering into the first cavity 360, this is by way of example only. Alternate embodiments could affix the motor 140 opposite the second cavity 365 such that it obscures air entering into the second cavity 365. In such an embodiment, the center openings 336 would allow air to pass from the first cavity 360 to the second cavity 365 when the air pressure in the second cavity 365 was lower than the air pressure in the first cavity 360, as described above.

In some embodiments, the disclosed air handler blower 301 could configures such that its location could be modified during installation or after installation to place the motor 140 on either side of the blower wheel 120. This allows for greater flexibility in the installation and operation of the disclosed air handler blower 301. However, regardless of which side of the blower wheel 120 the motor 140 is installed or later moved, the blower wheel 1120 will operate to equalize pressure between the two cavities 360, 365.

To the extent that air movers are used in the center plate 330, these air movers can either be arranged to function properly regardless of the placement of the motor 140, or the air movers or general system parameters can be modified when the motor 140 is installed or moved such that the air movers will move air in desired direction.

Center Plate

FIG. 8 is a plan view of a center plate 330 in a blower wheel 120 having multiple triangular openings 336 according to disclosed embodiments. As shown in FIG. 8, the center plate 330 is circular in shape and includes an axle hole 333 and a plurality of center openings 336.

The center plate 330 has a radius substantially equal to the radius of the blower wheel and forms a divider between a first blower side 320 of the blower wheel 120 and a second blower side 325 of the blower wheel 120. The center plate 330 can be made of metal, plastic, or any material having sufficient tensile strength to support the blower wheel 120.

In various embodiments, the center plate 330 can be substantially flat or can have portions that are not coplanar. For example, one embodiment might have a center portion formed at a different level than peripheral portions. In such case, some of the center plate would be slanted between the different levels used.

The axle hole 333 is formed in the middle of the center plate 330 overlapping a center line of the blower wheel 120. The axle hole 333 is provided for the axle 150 to pass through and be secured to the center plate 330. By making the axle hole 333 overlap the centerline of the blower wheel 120, this allows the axle 150 to rotate the center plate 330 around its center point, thereby rotating the entire blower wheel 120.

Although the embodiments discussed above all include an axle hole 333, this is by way of example only. Alternate embodiments could employ a different mechanism for securing the axle 150 to the center plate 330. For example, the first side of the center plate 330 could include a securing mechanism such as a clamp, or bolts, or the like that allow the axle 150 to be secured to the center plate 330 without passing through the center plate 330 such that it can rotate the center plate 330 around its center point.

In the embodiment of FIG. 8, the center openings 336 are triangular and are formed in a regular pattern surrounding the axle hole 333. The center openings 336 are arranged to be large enough to allow sufficient air to pass from the second cavity 365 to the first cavity 360 during operation, but small enough that their presence will not undermine the structural integrity of the center plate 330. The actual size of the center openings 336 can be varied in different embodiments.

In the embodiment of FIG. 8, the center openings 336 are formed in a regular pattern surrounding the axle hole 333. This regularity in location allows for a smoother transition of air between the second cavity 365 and the first cavity 360. However, this regular arrangement of the center openings 336 is by way of example only. Alternate embodiments could have center openings 336 arranged in an irregular pattern or a different regular pattern.

In the embodiment of FIG. 8, the center openings 336 are all formed to be of roughly the same size and shape. This regularity in size and shape allows for a smoother transition of air between the second cavity 365 and the first cavity 360. However, the regular size and shape of the center openings 336 is by way of example only. Alternate embodiments could have center openings 336 in the center plate 330 that are of different sizes and of different shapes. For example, one embodiment could have a mix of center openings 336 that are triangles, squares, circles and any other shape desired, regular or irregular.

FIG. 9 is a side view of the center plate 330 of FIG. 8 along the line IX-IX′ according to disclosed embodiments. As shown in FIG. 9, the portion of the center plate 330 that is shown is substantially flat and the center opening 336 is formed in the center plate 330 to allow the passage of transfer air 380 from one side of the center plate 330 to the other side of the center plate 330.

FIG. 10 is a plan view of a center plate 1030 in a blower wheel 120 having multiple circular openings 1036 according to disclosed embodiments. As shown in FIG. 10, the center plate 1030 is circular in shape and includes an axle hole 1033 and a plurality of center openings 1036.

The center plate 1030 has a radius substantially equal to the radius of the blower wheel 120 and forms a divider between a first blower side 320 of the blower wheel 120 and a second blower side 325 of the blower wheel 120. The center plate 1030 can be made of metal, plastic, or any material having sufficient tensile strength to support the blower wheel 120.

In various embodiments, the center plate 1030 can be substantially flat or can have portions that are not coplanar. For example, one embodiment might have a center portion formed at a different level than peripheral portions. In such case, some of the center plate would be slanted between the different levels used.

The axle hole 1033 is formed in the middle of the center plate 1030 overlapping a center line of the blower wheel 120. The axle hole 1033 is provided for the axle 150 to pass through and be secured to the center plate 1030. By making the axle hole 1033 overlap the centerline of the blower wheel 120, this allows the axle 150 to rotate the center plate 1030 around its center point, thereby rotating the entire blower wheel 120.

Although the embodiments discussed above all include an axle hole 1033, this is by way of example only. Alternate embodiments could employ a different mechanism for securing the axle 150 to the center plate 330. For example, the first side of the center plate 1030 could include a securing mechanism such as a clamp, or bolts, or the like that allow the axle 150 to be secured to the center plate 1030 such that it can rotate the center plate 1030 around its center point.

In the embodiment of FIG. 10, the center openings 1036 are circular and are formed in a regular pattern surrounding the axle hole 1033. The center openings 1036 are arranged to be large enough to allow sufficient air to pass from the second cavity 365 to the first cavity 360 during operation, but small enough that their presence will not undermine the structural integrity of the center plate 1030. The actual size of the center openings 336 can be varied in different embodiments.

In the embodiment of FIG. 10, the center openings 1036 are formed in a regular pattern surrounding the axle hole 1033. This regularity in location allows for a smoother transition of air between the second cavity 365 and the first cavity 360. However, this regular arrangement of the center openings 1036 is by way of example only. Alternate embodiments could have center openings 1036 arranged in an irregular pattern.

In the embodiment of FIG. 10, the center openings 1036 are all formed to be of roughly the same size and shape. This regularity in size and shape allows for a smoother transition of air between the second cavity 365 and the first cavity 360. However, this regular size and shape of the center openings 1036 is by way of example only. Alternate embodiments could have center openings 1036 in the center plate 1030 that are of different sizes and of different shapes. For example, one embodiment could have a mix of center openings 1036 that are triangles, squares, circles and any other shape desired, regular or irregular.

Furthermore, although the embodiment of FIG. 8 shows the use of triangular center openings 336 and the embodiment of FIG. 10 shows the use of circular center openings 1036, this is by way of example only. Alternate embodiments could use other shapes. These shapes could be regular or irregular and could be the same or different across the center plate 330, 1030.

FIG. 11 is a plan view of a center plate structure in a blower wheel 120 having first and second center plates 1130, 1132 connected by spokes 1137 according to disclosed embodiments.

As shown in FIG. 11, the first center plate 1130 is a first circular plate with a large center opening 1136. The second center plate 1132 is a second circular plate with an axle hole 1133 formed in it. The second center plate 1132 is arranged inside the large center opening 1136.

The radius of the second center plate 1132 is smaller than the radius of the center opening 1136 in the first center plate 1130. As a result, when the second center plate 1132 is placed inside the center opening 1136, there will be a gap between the second center plate 1132 and the first center plate 1130.

The first center plate 1130 has a radius substantially equal to the radius of the blower wheel 120. Together the first and second center plates 1130, 1132 form a divider between a first blower side 320 of the blower wheel 120 and a second blower side 325 of the blower wheel 120. The first and second center plates 1130, 1132 can be made of metal, plastic, or any material having sufficient tensile strength to support the blower wheel 120.

In order to keep the second center plate 1132 in place, a plurality of spokes 1137 secure the second center plate 1132 to the first center plate 1130. Specifically, the plurality of spokes 1137 are arranged around a circumference of the second center plate 1132. Each spoke is affixed to the first center plate 1130 by a first fastener 1138 and is affixed to the second center plate 1132 by a second fastener 1139. The spokes 1137 and the first and second fasteners 1138, 1139 should be strong enough and solidly enough secured that rotation of the second center plate 1132 by the axle 150 can be transferred to the first center plate 1130 and thereby the rest of the blower wheel 120 without deforming any part of the blower wheel 120.

The axle hole 1133 is formed in the middle of the second center plate 1332 overlapping a center line of the blower wheel 120. The axle hole 1133 is provided for the axle 150 to pass through and be secured to the second center plate 1132. By making the axle hole 1133 overlap the centerline of the blower wheel 120, this allows the axle 150 to rotate the second center plate 1332 around its center point, thereby rotating the entire blower wheel 120.

Although the embodiments discussed above all include an axle hole 1133, this is by way of example only. Alternate embodiments could employ a different mechanism for securing the axle 150 to the second center plate 1132. For example, the first side of the second center plate 1132 could include a securing mechanism such as a clamp, or bolts, or the like that allow the axle 150 to be secured to the second center plate 1132 such that it can rotate the second center plate 1132 around its center point.

In the embodiment of FIG. 11, an air opening (or gap) is formed by the gap between the circumference of the center opening 1136 in the first center plate 1130 and the circumference of the second center plate 1132. This air opening is arranged to be large enough to allow sufficient air to pass from the second cavity 365 to the first cavity 360 during operation. The actual size of the air opening formed between the first center plate 1130 and the second center plate 1132 can be varied in different embodiments.

In the embodiment of FIG. 11, both the center opening 1136 and the second center plate 1132 are formed to have a circular shape. However, these circular shapes are by way of example only. Alternate embodiments could vary the shape of the center opening 1136 and the second center plate 1132 as desired provided that an air gap was formed between the circumference of the center opening 1136 and the circumference of the second center plate 1132. In various embodiments the second center plate 1132 and the center opening 1136 can have either a regular or irregular shape. Furthermore, these two shapes need not be the same shape.

FIG. 12 is a plan view of a center plate 1230 in a blower wheel 120 having multiple triangular openings 1236 and blades 1234 formed adjacent to each opening 1236 according to disclosed embodiments. As shown in FIG. 12, the center plate 1230 is circular in shape and includes an axle hole 1233 and a plurality of center openings 1236.

The center plate 1230 has a radius substantially equal to the radius of the blower wheel 120 and forms a divider between a first lower side 320 of the blower wheel 120 and a second blower side 325 of the blower wheel 120. The center plate 1230 can be made of metal, plastic, or any material having sufficient tensile strength to support the blower wheel 120.

In various embodiments, the center plate 1230 can be substantially flat or can have portions that are not coplanar. For example, one embodiment might have a center portion formed at a different level than peripheral portions. In such case, some of the center plate would be slanted between the different levels used.

The axle hole 1233 is formed in the middle of the center plate 1230 overlapping a center line of the blower wheel 120. The axle hole 1233 is provided for the axle 150 to pass through and the secured to the center plate 1230. By making the axle hole 1233 overlap the centerline of the blower wheel 120, this allows the axle 150 to rotate the center plate 1230 around its center point, thereby rotating the entire blower wheel 120.

Although the embodiments discussed above all include an axle hole 1233, this is by way of example only. Alternate embodiments could employ a different mechanism for securing the axle 150 to the center plate 1230. For example, the first side of the center plate 1230 could include a securing mechanism such as a clamp, or bolts, or the like that allow the axle 150 to be secured to the center plate 1230 such that it can rotate the center plate 1230 around its center point.

In the embodiment of FIG. 12, the center openings 1236 are triangular and are formed in a regular pattern surrounding the axle hole 1233. The center openings 1236 are arranged to be large enough to allow sufficient air to pass from the second cavity 365 to the first cavity 360 during operation, but small enough that their presence will not undermine the structural integrity of the center plate 1230. The actual size of the center openings 1236 can be varied in different embodiments.

In the embodiment of FIG. 12, the center openings 1236 are formed in a regular pattern surrounding the axle hole 1233. This regularity in location allows for a smoother transition of air between the second cavity 365 and the first cavity 360. However, this regular arrangement of the center openings 1236 is by way of example only. Alternate embodiments could have center openings 1236 arranged in an irregular pattern.

In the embodiment of FIG. 12, the center openings 1236 are all formed to be of roughly the same size and shape. This regularity in size and shape allows for a smoother transition of air between the second cavity 365 and the first cavity 360. However, this regular size and shape of the center openings 1236 is by way of example only. Alternate embodiments could have center openings 1236 in the center plate 1230 that are of different sizes and of different shapes. For example, one embodiment could have a mix of center openings 1236 that are triangles, squares, circles and any other shape desired, regular and irregular.

In the embodiment of FIG. 12, each center opening 1236 has a blade 1234 formed adjacent to it. These blades 1234 act as air movers to assist the movement of air from one side of the center plate 1230 to the other side of the center plate 1230. These blades 1234 are provided as an example of an air mover. However, different air movers can be used in different embodiments. For example, some alternate embodiments could use air scoops, louvers, or adjustable blades in place of the fixed blades 1234 disclosed in FIG. 12.

For ease of discussion, the blades 1234 will be described as being configured to move air from the second cavity 365 to the first cavity 360. However, this is by way of example only. In alternate embodiments the blades 1234 could be configured to move air from the first cavity 360 to the second cavity 365. In different embodiments the particular configuration of the blades 1234 may be reversed if the air flow should go in the opposite direction.

In the embodiment of FIG. 12, the blades 1234 are triangular in shape and are roughly the same size and shape as the center openings 1236. Each blade 1234 is affixed on one edge to a side of a corresponding center opening 1236 and extends away from the center plate 1230 at an angle between 0 and 90 degrees. In various embodiments the blades 1234 can be extended either into the first cavity 360 or into the second cavity 365. These blades 1234 operate to move air from the second cavity 365 into the first cavity 360 when the center plate 1230 rotates.

If the blades 1234 extend into the second cavity 365, then the elevated end of the blade 1234 will be located in the direction of rotational motion of the center plate 1230. In this way, when the center plate 1230 rotates, the blade pushes against the air in the second cavity 365 and deflects the air from the second cavity 365, through the associated center opening 1236, and into the first cavity 360.

If the blades 1234 extend into the first cavity 360, then the elevated end of the blade 1234 will be located in the direction opposite to the direction of rotations motion of the center plate 1230. In this way, when the center plate 1230 rotates, the blade 1234 pushes against the air in the first cavity 360 and deflects it away from the associated center opening 1236. This will cause an area of increased negative pressure 1240 rotationally behind the blade 1234 in proximity to the associated center opening 1236. This area of increased negative pressure 1240 will then draw air from the second cavity 365, through the associated center opening 1236, and into the first cavity 360.

In the embodiment of FIG. 12, the blades 1234 are formed to be roughly the same size and shape as the center openings 1136. This allows for easy formation of the blades 1234 and center openings 1236 by starting with a solid circular plate and cutting out two sides of each center opening 1236. The plate material that filled each center opening 1236 can then be bent away from the center plate 1230 in a relevant direction along the edge still attached to the center plate 1230. This will both expose the center opening 1236 and form the blade 1234 properly angled to move air through the associated center opening 1236 when the center plate 1230 rotates.

However, having the blades 1234 be roughly the same size and shape as the center openings 1236 is by way of example only. Alternate embodiments could use blades 1234 that are larger or smaller than the associated center opening 1236. Alternate embodiments could also use blades 1234 that have a different shape than the associated center opening 1236.

In addition, although the embodiment of FIG. 12 discloses that each center opening 1236 has a blade 1234 associated with it, this is by way of example only. In some alternate embodiments only some of the center openings 1236 will have blades 1234 associated with them. For example, one alternate embodiment might have every other center opening 1236 associated with a blade. Other configurations are possible.

FIG. 13 is a side view of the center plate 1230 of FIG. 12 along line XII-XII′ in which the blades 1234 are each arranged to push air through an associated center opening 1236 when the center plate 1230 rotates according to disclosed embodiments. As shown in FIG. 13, the portion of the center plate 1230 that is shown is substantially flat and the center opening 1236 is formed in the center plate 1230 to allow the passage of transfer air 380 from the second cavity 365 on one side of the center plate 1230 to the first cavity 360 on the other side of the center plate 1230. The blade 1234 is formed to be connected at one edge to a side of an associated center opening 1236 and at an angle between 0 and 90 degrees from the center plate 1230 extending into the second cavity 365.

As the center plate 1230 rotates, the blade 1234 will cut through the air in the second cavity 365, pushing against the air and deflecting it as transfer air 380 through the associated center opening 1236 and into the first cavity 360. In this way the blade 1234 acts as an air mover associated with the center opening 1236. The movement of air caused by the blade 1234 deflecting the transfer air 380 from the second cavity 365 into the first cavity 360 is in addition to any movement of transfer air 380 caused by the equalizing of air pressure between the first and second cavities 360, 365. By having the blades 1234 as air movers, the center plate 1230 of FIG. 13 can increase the air flow of the transfer air 380 as compared to a center plate without the blades 1234.

FIG. 14 is a side view of the center plate 1230 of FIG. 12 along line XII-XII′ in which the blades 1234 are arranged to create an area of increased negative air pressure 1240 what will draw air through an associated center opening 1236 when the center plate 1230 rotates according to disclosed embodiments. As shown in FIG. 14, the portion of the center plate 1230 that is shown is substantially flat and the center opening 1236 is formed in the center plate 1230 to allow the passage of transfer air 380 from the second cavity 365 on one side of the center plate 1230 to the first cavity 360 on the other side of the center plate 1230. The blade 1234 is formed to be connected at one edge to a side of an associated center opening 1236 and at an angle between 0 and 90 degrees from the center plate 1230 extending into the first cavity 360.

As the center plate 1230 rotates, the blade 1234 will push against the air in the first cavity 360, deflecting it away from the associated center opening 1236 and causing an area of increased negative air pressure 1240 rotationally behind the blade 1234 and in proximity to the associated center opening 1236. Even if the air in the first cavity 360 already has a lower air pressure than the air in the second cavity 365 the air pressure rotationally behind the blade 1234 will be even lower causing the transfer air 380 to be drawn from the second cavity 365 to the first cavity 360. The operation of the blade 1234 will therefore increase the speed at which transfer air 380 will be drawn from the second cavity 365 to the first cavity 360. In this way the blade 1234 acts as an air mover associated with the center opening 1236. The movement of air caused by the blade 1234 creating area of reduced negative air pressure 1240 is in addition to any movement of transfer air 380 caused by the equalizing of air pressure between the first and second cavities 360, 365. By having the blades 1234 as air movers, the center plate 1230 of FIG. 13 can increase the air flow of the transfer air 380 as compared to a center plate without the blades 1234.

Operation of an Air Handler Blower

FIG. 15 is a flow chart 1500 showing the operation of an air handler blower according to disclosed embodiments. In this embodiment, the air handler blower includes a blower wheel. The blower wheel is a hollow cylinder with a first blower side having a first cavity and a second blower side having a second cavity. The first cavity is defined by a first cylindrical blade assembly and the second cavity is defined by a second cylindrical blade assembly. The first blower side and the second blower side are divided by a center plate that has one or more center openings in it that facilitate the flow of air between the first cavity and the second cavity.

As shown in FIG. 15, operation begins when the blower wheel is rotated (1510).

The rotation of the blower wheel will cause first intake air to be drawn into the first cavity (1520) and second intake air to be drawn into the second cavity (1530). In this embodiment, the first intake air will have a greater airflow than the second intake air.

A portion of the second intake air will be passed from the second cavity to the first cavity to generate first increased intake air in the first cavity and second decreased intake air in the second cavity (1540). This passing of the second intake air from the second cavity to the first cavity can be performed by passing air through the one or more center openings in the center plate. This operation can be assisted by the operation of air movers.

The first increased intake air is then moved from the first cavity to an outer circumference of the first cylindrical blade assembly as first exhaust air (1550). This can be done by having the first cylindrical blade assembly draw the first increased intake air out of the first cavity and passing it to the circumference of the first cylindrical blade assembly as the first exhaust air.

The second decreased intake air is then moved from the second cavity to an outer circumference of the second cylindrical blade assembly as second exhaust air (1560). This can be done by having the second cylindrical blade assembly draw the second decreased intake air out of the second cavity and passing it to the circumference of the second cylindrical blade assembly as the second exhaust air.

Finally, the first exhaust air and the second exhaust air are combined to form combined exhaust air (1570). This final exhaust air can be provided to an air handler for heating or cooling.

In some circumstances, the second intake air may have a greater airflow than the second intake air. For example, this may happen if an opening into the first cavity is obscured by a motor that is used to rotate the blower wheel. Without correction, this could cause the first exhaust air to be reduced by a greater amount than the second exhaust air would be increased, thereby reducing the general efficiency of the air handler blower.

However, by passing a portion of the second intake air from the second cavity to the first cavity, this operation can be fully or partially closer in airflow to the equalize the first and second intake air, making the first increased intake air roughly comparable to the second decreased intake air. As a result, the first and second exhaust air will be roughly comparable in air flow, maintaining a high efficiency for the air handler blower.

CONCLUSION

This disclosure is intended to explain how to fashion and use various embodiments in accordance with the invention rather than to limit the true, intended, and fair scope and spirit thereof. The foregoing description is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications or variations are possible in light of the above teachings. The embodiment(s) was chosen and described to provide the best illustration of the principles of the invention and its practical application, and to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims, as may be amended during the pendency of this application for patent, and all equivalents thereof, when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled. The various circuits described above can be implemented in discrete circuits or integrated circuits, as desired by implementation.

AIR HANDLER BLOWER AND METHOD OF OERATING THE SAME

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CPC

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Abstract

Description

Claims