This application is directed, in general, to air handlers, and methods of manufacturing thereof.
The indoor unit of an air conditioning system, which often is referred to as an air handler, typically includes multiple components that are located in a common cabinet. For certain applications, it is desirable to fit such components into a compact a cabinet while still maintaining efficient air handling capabilities.
One embodiment of the present disclosure is an air handler system, comprising a cabinet housing a blower unit and a heat exchange unit. The blower unit and the heat exchange unit are located in a substantially same lateral dimension in the cabinet. The blower unit and the heat exchange unit are separated by a distance that provides for a substantially uniform flow of air through a vertically-orientated plane of the heat exchange unit when the blower unit is in operation.
Another embodiment of the present disclosure is a method of manufacturing an air handler system. The method includes providing a cabinet, attaching a blower unit to the cabinet and attaching a heat exchange unit to the cabinet. The blower unit and the heat exchange unit are located in a substantially same lateral dimension in the cabinet. The blower unit and the heat exchange unit are separated by a distance that provides for a substantially uniform flow of air through a vertically-orientated plane of the heat exchange unit when the blower unit is in operation.
Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
Embodiments of the present disclosure benefit from the discovery that the heat exchange and blower units of an air handler system can be substantially laterally co-located within a cabinet space without detrimentally affecting the air flow characteristics in the air handler. In particular, the judicious selection of the lateral distance between the heat exchange unit and blower unit facilitates having uniform and acceptably high air flow characteristics through the heat exchange unit, thereby providing acceptable heat transfer capabilities. Consequently, the cabinet of the air handler system can be substantially reduced in height compared to conventional air handlers with similar heat transfer capabilities. This, in turn, beneficially allows the air handler system to be located in a more compact cabinet space than hitherto feasible using conventional air handler systems where the blower is often located above the heat exchange unit.
One embodiment of the present disclosure is an air handler system.
With continuing reference to
The term, distance, as used herein, refers to the distance (e.g., distance 125 in
The term “located in a substantially same lateral dimension” as used herein means that a substantial amount (e.g., at least about 10 percent) of the area of the vertically-orientated plane 130 of the heat exchange unit 115 projected in the lateral dimension 120, overlaps with the opposing vertically-oriented surface 140 of the blower unit. For instance,
For embodiments of the system 100, the fine adjustment of the distance 125 between the blower unit 110 and the heat exchanger unit 115 is an important and newly recognized result effective variable that affects the uniformity and absolute air flow through the heater exchanger unit.
In some cases, if the distance 125 is closer than the target value, then moisture can be undesirably pulled into duct work 150 (
One of ordinary skill in the art would recognize that the actual target value depends upon several factors such as the sizes of the cabinet, blower unit, heat exchange. As such, the target value of the distance 125 is determined empirically for the particular air handler system 100 under consideration. For example, for some embodiments of the system 100, the distance 125 is at a value within about ±0.5 inches of a target value in a range of about 2 to 4 inches.
The term, substantially uniform flow of air, as used herein means that, when the blower unit 110 in operation, the velocity of air flow through any one of a two-percent or higher area portion (termed an “area cell” herein) of the vertically-oriented plane 130 is substantially the same as the velocity of air flow through any other two-percent or higher area portion of the vertically-oriented plane 130 of the heat exchange unit 115.
For instance, consider an example heat exchange unit 115 of the system 100, such as depicted in
For instance, in some embodiments of the system 100, when the blower unit 110 is operating, the distance 125 between the heat exchange unit 115 and blower unit 110 provides for a velocity of air, passing though any individual area cell (e.g., area cells 310, 312, 314) of the vertically-oriented plane 130, that is a value within a range of about 400 to 800 cubic feet per minute.
In some embodiments of the system 100, when the blower unit is operating, the distance 125 between the heat exchange unit 115 and blower unit 110 provides for an average velocity of air passing through the vertically-oriented plane 130 of at least about 400 cubic feet per minute, and more preferably, an average velocity of at least about 475 cubic feet per minute.
For illustrative purposes,
Various embodiments of the system 100 may have additional features which facilitate providing a compact design with the desired uniform and acceptably high air flow characteristics.
For some embodiments of the system 100, the heat exchanger 115 can advantageously include louvered fins, such as described in U.S. Pat. No. 5,042,576 which is incorporated in its entirety herein. It is believed that the plurality of slits present in such louvered fins helps to prevent condensate from being pulled up into duct work 150 (
As further illustrated in
In some embodiments of the system 100, the blower unit 110, includes, or is, a centrifugal blower. In some cases, a rotating drum 160 of the centrifugal blower 110 is oriented such the axis of rotation of the drum 165 is perpendicular to the vertically-oriented plane 130, and air output 167 from the centrifugal blower 110 is directed to an air duct 150 located on a top side 170 of the cabinet 105. Other embodiments could include other types of blower units such a fan blower. Some embodiments of the blower unit 110 can further include an electrical heater unit 210. For example, the blower unit 110 can include an electric heater unit incorporated such as described in U.S. Pat. No. 6,950,606 which is incorporated in its entirety herein.
Some embodiments of the system 100, the cabinet 105 is configured as a wall-mounted cabinet. In some cases, to facilitate fitting the system 100 into a compact space, the cabinet 105 has a compact vertical height 180 of about 30 inches or less. For instance, in some cases the cabinet 105 is configured to be located in a closet, wherein the ceiling height of the closet equals about 8 feet. In some cases, the cabinet 105 can be located above a water heater that is also located inside the closet and which has a vertical height of about 36 inches.
One of ordinary skill in the art would appreciate that embodiments of the air handler system 100 could include other components to facilitate its operation. For example, the system 100 can include a drain pan 185 located below the heat exchanger unit 115. For example, the system 100 can include an electrical control board 190 that is configured to control the operation of the blower unit 110, the heat exchange unit 115 and other components of the system 100.
Another embodiment of the present disclosure is a method of manufacturing an air handler system.
With continuing reference to
In some embodiments of the method 500, attaching the heat exchange unit 115 to the cabinet 105 in step 520 can further include a step 525 of incrementally adjusting the distance 125. For each incrementally adjusted distance 125, measuring the velocity of air passing through different area cells (e.g., cells 310, 312, 316) of the vertically-orientated plane 130 when the blower unit 110 is in operation. For example, in some cases, incrementally adjusting the distance 125 includes incremental adjustments of about 0.5 inches or less.
In other embodiments of the method 500, however, the distance 125 could alternatively, or additionally, be adjusted in step 525 as part of attaching the blower unit 110 to the cabinet 105 (step 515).
In some embodiments of the method 500 attaching the heat exchange unit 115 to the cabinet 105 in step 520 can further include a step 530 of adjusting an angle 195 of the vertically-orientated plane 130. For example, in some embodiments, to facilitate attaining a more uniform air flow 117, or fitting the heat exchanger in a compact-height cabinet 105, it may be desirable to adjust the angle 195 to a value in a range of about ±5 degree from a perpendicular angle (e.g., an angle 195 in a range 95 to 85 degrees) with respect to a horizontal base 197 of the cabinet 105. Adjusting the angle 195 away from a perpendicular angle, however, is balanced against introducing excessive moisture into the output air flow 167 of the system 100.
One of ordinary skill in the art would appreciate that the method of manufacture 500 could further include attaching other components (e.g., ducts 150, 155, drain pan 185, control box 190) to the cabinet 105, or to other components of the system, to complete the manufacture of the system 100.
Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments.
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