DIVERTER BAFFLE FOR A BLOWER

BACKGROUND

The present disclosure generally relates to a heating, ventilation, and/or air conditioning (HVAC) system and, more particularly, to a diverter baffle for a blower of the HVAC system.

This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present techniques, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

An HVAC system may be used to thermally regulate an environment, such as the interior space of a building, home, or other structure. The HVAC system generally includes a vapor compression system having heat exchangers, such as a condenser and an evaporator, which cooperate to transfer thermal energy between the HVAC system and the environment. In some instances, the HVAC system includes a blower that forces air over a heat exchanger. For example, the blower may be configured to force air across or through the heat exchanger. In some instances, the blower may not be configured to force air directly across or through the heat exchanger. Instead, the blower may be positioned to output an air flow that impinges against a wall or other panel of an HVAC system before the air is directed across or through the heat exchanger, which may inhibit blower performance and/or may reduce efficiency of air flow through the HVAC system.

SUMMARY

A summary of certain embodiments disclosed herein is set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.

In one embodiment, a discharge section of a heating, ventilation, and/or air conditioning (HVAC) system, includes a first wall defining an opening configured to receive an air flow from a blower of the HVAC system, a second wall spaced apart from and disposed opposite the first wall, and a diverter baffle disposed at an oblique angle relative to the first wall and the second wall and configured to divert the air flow received through the opening.

In another embodiment, a heating section of a heating, ventilation, and/or air conditioning (HVAC) system includes a first wall defining an opening configured to receive an air flow from a blower of the HVAC system, a second wall spaced apart from and disposed opposite the first wall, and a diverter baffle including a first end coupled to the first wall and a second end coupled to the second wall. The first end is offset from the opening and the second end is substantially aligned with the opening relative to the air flow through the opening.

In yet another embodiment, a discharge section of a heating, ventilation, and/or air conditioning (HVAC) system includes a first wall defining an opening having a central axis, a second wall spaced apart from and disposed opposite the first wall, and a diverter baffle extending from the first wall to the second wall. The opening of the first wall is configured to receive an air flow from a blower of the HVAC system along an air flow path having a portion extending along the central axis. The diverter baffle is disposed at an oblique angle relative to the first wall and the second wall, and the diverter baffle extends into the portion of the air flow path to redirect the air flow.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects of the present disclosure may be better understood upon reading the following detailed description and upon reference to the drawings, in which:

FIG. 1 is a perspective view of an embodiment of a heating, ventilation, and/or air conditioning (HVAC) system for building environmental management that may employ one or more HVAC units, in accordance with an aspect of the present disclosure;

FIG. 2 is a perspective view of an embodiment of a packaged HVAC unit, in accordance with an aspect of the present disclosure;

FIG. 3 is a perspective view of an embodiment of a residential, split HVAC system, in accordance with an aspect of the present disclosure;

FIG. 4 is a schematic of an embodiment of a vapor compression system that may be used in an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 5 is a perspective view of an embodiment of a discharge section and a blower section of an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 6 is a perspective view of an embodiment of a discharge section and a blower section of an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 7 is a side view of an embodiment of a discharge section and a blower section of an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 8 is a side view of an embodiment of a discharge section and a blower section of an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 9 is a top view of an embodiment of a discharge section and a blower section of an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 10 is a perspective view of an embodiment of a discharge section and a blower section of an HVAC system, in accordance with an aspect of the present disclosure; and

FIG. 11 is a top view of an embodiment of a discharge section and a blower section of an HVAC system, in accordance with an aspect of the present disclosure.

DETAILED DESCRIPTION

One or more specific embodiments of the present disclosure will be described below. These described embodiments are only examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but may nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

Generally, a heating, ventilation, and/or air conditioning (HVAC) system may control climate conditions, such as temperature and/or humidity, within a building or other conditioned space. The HVAC system may include a blower(s) and/or other mechanisms configured to force or draw air through the HVAC system to control the temperature and the humidity. For example, the blower may move air from one section of the HVAC system to another section of the HVAC system. Additionally, the blower may move the air toward a heat exchanger of the HVAC system. For example, a blower section including the blower may receive an air flow from another section, such as a section including an evaporator or a condenser. The blower may move the air from the blower section to a heating section, a discharge section, and/or another section of the HVAC system.

In some instances, the blower may force the air directly toward the heat exchanger and/or toward another component of the HVAC system, such as a wall of an adjacent section. For example, the wall may be generally perpendicular to the flow path of the air from the blower, the blower may direct the air to impinge against the wall, and the air may then be directed in multiple directions by the wall. For example, the wall may direct the air away from the heat exchanger disposed adjacent to the wall and/or elsewhere within the section formed by the wall. As such, forcing the air flow onto the wall may inhibit heating of the air flow within a heating section, may inhibit blower performance, and/or may reduce efficiency of air flow through the HVAC system. It is now recognized that inclusion of a diverter baffle configured to more acutely direct the air flow toward the heat exchanger and/or an outlet of the section may improve blower operation, air flow through the HVAC system, and efficiency of the HVAC system.

Accordingly, the present disclosure provides systems including a diverter baffle configured to divert an air flow, such as the air flow output by a blower of the HVAC system. As discussed in detail below, the disclosed techniques enable the HVAC system to efficiently direct the air flow through a heating section and/or a discharge section, in some embodiments. For example, the diverter baffle may direct the air flow from the blower toward a heat exchanger disposed within a heating section and/or toward an opening configured to discharge the air flow from a discharge section. In so doing, the diverter baffle also improves operation of the blower. For example, the inclusion of the diverter baffle may enable the blower to utilize less power to achieve a desired level of air flow. As such, the systems described herein improve air flow through the HVAC system and increase efficient operation of the HVAC system.

Turning now to the drawings, FIG. 1 illustrates an embodiment of a heating, ventilation, and/or air conditioning (HVAC) system for environmental management that may employ one or more HVAC units. As used herein, an HVAC system includes any number of components configured to enable regulation of parameters related to climate characteristics, such as temperature, humidity, air flow, pressure, air quality, and so forth. For example, an “HVAC system” as used herein is defined as conventionally understood and as further described herein. Components or parts of an “HVAC system” may include, but are not limited to, all, some of, or individual parts such as a heat exchanger, a heater, an air flow control device, such as a fan, a sensor configured to detect a climate characteristic or operating parameter, a filter, a control device configured to regulate operation of an HVAC system component, a component configured to enable regulation of climate characteristics, or a combination thereof. An “HVAC system” is a system configured to provide such functions as heating, cooling, ventilation, dehumidification, pressurization, refrigeration, filtration, or any combination thereof. The embodiments described herein may be utilized in a variety of applications to control climate characteristics, such as residential, commercial, industrial, transportation, or other applications where climate control is desired.

In the illustrated embodiment, a building 10 is air conditioned by a system that includes an HVAC unit 12. The building 10 may be a commercial structure or a residential structure. As shown, the HVAC unit 12 is disposed on the roof of the building 10; however, the HVAC unit 12 may be located in other equipment rooms or areas adjacent the building 10. The HVAC unit 12 may be a single package unit containing other equipment, such as a blower, integrated air handler, and/or auxiliary heating unit. In other embodiments, the HVAC unit 12 may be part of a split HVAC system, such as the system shown in FIG. 3, which includes an outdoor HVAC unit 58 and an indoor HVAC unit 56.

In any case, the HVAC unit 12 may be an air cooled device that implements a refrigeration cycle to provide conditioned air to the building 10. For example, the HVAC unit 12 may include one or more heat exchangers across which an air flow is passed to condition the air flow before the air flow is supplied to the building. In the illustrated embodiment, the HVAC unit 12 is a rooftop unit (RTU) that conditions a supply air stream, such as environmental air and/or a return air flow from the building 10. After the air is conditioned, the HVAC unit 12 may supply the conditioned air to the building 10 via ductwork 14 extending throughout the building 10 from the HVAC unit 12. For example, the ductwork 14 may extend to various individual floors or other sections of the building 10. In some embodiments, the HVAC unit 12 may include a heat pump that provides both heating and cooling to the building 10, for example, with one refrigeration circuit implemented to operate in multiple different modes. In other embodiments, the HVAC unit 12 may include one or more refrigeration circuits for cooling an air stream and a furnace for heating the air stream.

A control device 16, one type of which may be a thermostat, may be used to designate the temperature of the conditioned air. The control device 16 also may be used to control the flow of air through the ductwork 14. For example, the control device 16 may be used to regulate operation of one or more components of the HVAC unit 12 or other equipment, such as dampers and fans, within the building 10 that may control flow of air through and/or from the ductwork 14. In some embodiments, other devices may be included in the system, such as pressure and/or temperature transducers or switches that sense the temperatures and pressures of the supply air, return air, and/or the like. Moreover, the control device 16 may include computer systems that are integrated with or separate from other building control or monitoring systems, and even systems that are remote from the building 10. In some embodiments, the HVAC unit 12 may operate in multiple zones of the building and may be coupled to multiple control devices that each control flow of air in a respective zone. For example, a first control device 16 may control the flow of air in a first zone 17 of the building, a second control device 18 may control the flow of air in a second zone 19 of the building, and a third control device 20 may control the flow of air in a third zone 21 of the building.

FIG. 2 is a perspective view of an embodiment of the HVAC unit 12. In the illustrated embodiment, the HVAC unit 12 is a single package unit that may include one or more independent refrigeration circuits and components that are tested, charged, wired, piped, and ready for installation. The HVAC unit 12 may provide a variety of heating and/or cooling functions, such as cooling only, heating only, cooling with electric heat, cooling with dehumidification, cooling with gas heat, or cooling with a heat pump. As described above, the HVAC unit 12 may directly cool and/or heat an air stream provided to the building 10 to condition a space in the building 10.

As shown in the illustrated embodiment of FIG. 2, a cabinet 24 or enclosure encloses the HVAC unit 12 and provides structural support and protection to the internal components from environmental and other contaminants. In some embodiments, the cabinet 24 may be constructed of galvanized steel and insulated with aluminum foil faced insulation. Rails 26 may be joined to the bottom perimeter of the cabinet 24 and provide a foundation for the HVAC unit 12. In certain embodiments, the rails 26 may provide access for a forklift and/or overhead rigging to facilitate installation and/or removal of the HVAC unit 12. In some embodiments, the rails 26 may fit into “curbs” on the roof to enable the HVAC unit 12 to provide air to the ductwork 14 from the bottom of the HVAC unit 12 while blocking elements such as rain from leaking into the building 10.

The HVAC unit 12 includes heat exchangers 28 and 30 in fluid communication with one or more refrigeration circuits. Tubes within the heat exchangers 28 and 30 may circulate refrigerant, such as R-410A, through the heat exchangers 28 and 30. The tubes may be of various types, such as multichannel tubes, conventional copper or aluminum tubing, and so forth. Together, the heat exchangers 28 and 30 may implement a thermal cycle in which the refrigerant undergoes phase changes and/or temperature changes as it flows through the heat exchangers 28 and 30 to produce heated and/or cooled air. For example, the heat exchanger 28 may function as a condenser where heat is released from the refrigerant to ambient air, and the heat exchanger 30 may function as an evaporator where the refrigerant absorbs heat to cool an air stream. In other embodiments, the HVAC unit 12 may operate in a heat pump mode where the roles of the heat exchangers 28 and 30 may be reversed. That is, the heat exchanger 28 may function as an evaporator and the heat exchanger 30 may function as a condenser. In further embodiments, the HVAC unit 12 may include a furnace for heating the air stream that is supplied to the building 10. While the illustrated embodiment of FIG. 2 shows the HVAC unit 12 having two of the heat exchangers 28 and 30, in other embodiments, the HVAC unit 12 may include one heat exchanger or more than two heat exchangers.

The heat exchanger 30 is located within a compartment 31 that separates the heat exchanger 30 from the heat exchanger 28. Fans 32 draw air from the environment through the heat exchanger 28. Air may be heated and/or cooled as the air flows through the heat exchanger 28 before being released back to the environment surrounding the HVAC unit 12. A blower assembly 34, powered by a motor 36, draws air through the heat exchanger 30 to heat or cool the air. The heated or cooled air may be directed to the building 10 by the ductwork 14, which may be connected to the HVAC unit 12. Before flowing through the heat exchanger 30, the conditioned air flows through one or more filters 38 that may remove particulates and contaminants from the air. In certain embodiments, the filters 38 may be disposed on the air intake side of the heat exchanger 30 to prevent contaminants from contacting the heat exchanger 30.

The HVAC unit 12 also may include other equipment for implementing the thermal cycle. Compressors 42 increase the pressure and temperature of the refrigerant before the refrigerant enters the heat exchanger 28. The compressors 42 may be any suitable type of compressors, such as scroll compressors, rotary compressors, screw compressors, or reciprocating compressors. In some embodiments, the compressors 42 may include a pair of hermetic direct drive compressors arranged in a dual stage configuration 44. However, in other embodiments, any number of the compressors 42 may be provided to achieve various stages of heating and/or cooling. As may be appreciated, additional equipment and devices may be included in the HVAC unit 12, such as a solid-core filter drier, a drain pan, a disconnect switch, an economizer, pressure switches, phase monitors, and humidity sensors, among other things.

The HVAC unit 12 may receive power through a terminal block 46. For example, a high voltage power source may be connected to the terminal block 46 to power the equipment. The operation of the HVAC unit 12 may be governed or regulated by a control board or controller 48. The control board 48 may include control circuitry connected to a thermostat, sensors, and alarms. One or more of these components may be referred to herein separately or collectively as the control device 16. The control circuitry may be configured to control operation of the equipment, provide alarms, and monitor safety switches. Wiring 49 may connect the control board 48 and the terminal block 46 to the equipment of the HVAC unit 12.

FIG. 3 illustrates a residential heating and cooling system 50, also in accordance with present techniques. The residential heating and cooling system 50 may provide heated and cooled air to a residential structure, as well as provide outside air for ventilation and provide improved indoor air quality (IAQ) through devices such as ultraviolet lights and air filters. In the illustrated embodiment, the residential heating and cooling system 50 is a split HVAC system. In general, a residence 52 conditioned by a split HVAC system may include refrigerant conduits 54 that operatively couple the indoor unit 56 to the outdoor unit 58. The indoor unit 56 may be positioned in a utility room, an attic, a basement, and so forth. The outdoor unit 58 is typically situated adjacent to a side of residence 52 and is covered by a shroud to protect the system components and to prevent leaves and other debris or contaminants from entering the unit. The refrigerant conduits 54 transfer refrigerant between the indoor unit 56 and the outdoor unit 58, typically transferring primarily liquid refrigerant in one direction and primarily vaporized refrigerant in an opposite direction.

When the system shown in FIG. 3 is operating as an air conditioner, a heat exchanger 60 in the outdoor unit 58 serves as a condenser for re-condensing vaporized refrigerant flowing from the indoor unit 56 to the outdoor unit 58 via one of the refrigerant conduits 54. In these applications, a heat exchanger 62 of the indoor unit 56 functions as an evaporator. Specifically, the heat exchanger 62 receives liquid refrigerant, which may be expanded by an expansion device, and evaporates the refrigerant before returning it to the outdoor unit 58.

The outdoor unit 58 draws environmental air through the heat exchanger 60 using a fan 64 and expels the air above the outdoor unit 58. When operating as an air conditioner, the air is heated by the heat exchanger 60 within the outdoor unit 58 and exits the unit at a temperature higher than it entered. The indoor unit 56 includes a blower or fan 66 that directs air through or across the indoor heat exchanger 62, where the air is cooled when the system is operating in air conditioning mode. Thereafter, the air is passed through ductwork 68 that directs the air to the residence 52. The overall system operates to maintain a desired temperature as set by a system controller. When the temperature sensed inside the residence 52 is higher than the set point on the thermostat, or a set point plus a small amount, the residential heating and cooling system 50 may become operative to refrigerate additional air for circulation through the residence 52. When the temperature reaches the set point, or a set point minus a small amount, the residential heating and cooling system 50 may stop the refrigeration cycle temporarily.

The residential heating and cooling system 50 may also operate as a heat pump. When operating as a heat pump, the roles of heat exchangers 60 and 62 are reversed. That is, the heat exchanger 60 of the outdoor unit 58 will serve as an evaporator to evaporate refrigerant and thereby cool air entering the outdoor unit 58 as the air passes over outdoor the heat exchanger 60. The indoor heat exchanger 62 will receive a stream of air blown over it and will heat the air by condensing the refrigerant.

In some embodiments, the indoor unit 56 may include a furnace system 70. For example, the indoor unit 56 may include the furnace system 70 when the residential heating and cooling system 50 is not configured to operate as a heat pump. The furnace system 70 may include a burner assembly and heat exchanger, among other components, inside the indoor unit 56. Fuel is provided to the burner assembly of the furnace system 70 where it is mixed with air and combusted to form combustion products. The combustion products may pass through tubes or piping in a heat exchanger, separate from heat exchanger 62, such that air directed by the blower 66 passes over the tubes or pipes and extracts heat from the combustion products. The heated air may then be routed from the furnace system 70 to the ductwork 68 for heating the residence 52.

FIG. 4 is an embodiment of a vapor compression system 72 that may be used in any of the systems described above. The vapor compression system 72 may circulate a refrigerant through a circuit starting with a compressor 74. The circuit may also include a condenser 76, an expansion valve(s) or device(s) 78, and an evaporator 80. The vapor compression system 72 may further include a control panel 82 that has an analog to digital (A/D) converter 84, a microprocessor 86, a non-volatile memory 88, and/or an interface board 90. The control panel 82 and its components may function to regulate operation of the vapor compression system 72 based on feedback from an operator, from sensors of the vapor compression system 72 that detect operating conditions, and so forth.

In some embodiments, the vapor compression system 72 may use one or more of a variable speed drive (VSDs) 92, a motor 94, the compressor 74, the condenser 76, the expansion valve or device 78, and/or the evaporator 80. The motor 94 may drive the compressor 74 and may be powered by the variable speed drive (VSD) 92. The VSD 92 receives alternating current (AC) power having a particular fixed line voltage and fixed line frequency from an AC power source, and provides power having a variable voltage and frequency to the motor 94. In other embodiments, the motor 94 may be powered directly from an AC or direct current (DC) power source. The motor 94 may include any type of electric motor that may be powered by a VSD or directly from an AC or DC power source, such as a switched reluctance motor, an induction motor, an electronically commutated permanent magnet motor, or another suitable motor.

The compressor 74 compresses a refrigerant vapor and delivers the vapor to the condenser 76 through a discharge passage. In some embodiments, the compressor 74 may be a centrifugal compressor. The refrigerant vapor delivered by the compressor 74 to the condenser 76 may transfer heat to a fluid passing across the condenser 76, such as ambient or environmental air 96. The refrigerant vapor may condense to a refrigerant liquid in the condenser 76 as a result of thermal heat transfer with the environmental air 96. The liquid refrigerant from the condenser 76 may flow through the expansion device 78 to the evaporator 80.

The liquid refrigerant delivered to the evaporator 80 may absorb heat from another air stream, such as a supply air stream 98 provided to the building 10 or the residence 52. For example, the supply air stream 98 may include ambient or environmental air, return air from a building, or a combination of the two. The liquid refrigerant in the evaporator 80 may undergo a phase change from the liquid refrigerant to a refrigerant vapor. In this manner, the evaporator 80 may reduce the temperature of the supply air stream 98 via thermal heat transfer with the refrigerant. Thereafter, the vapor refrigerant exits the evaporator 80 and returns to the compressor 74 by a suction line to complete the cycle.

In some embodiments, the vapor compression system 72 may further include a reheat coil in addition to the evaporator 80. For example, the reheat coil may be positioned downstream of the evaporator relative to the supply air stream 98 and may reheat the supply air stream 98 when the supply air stream 98 is overcooled to remove humidity from the supply air stream 98 before the supply air stream 98 is directed to the building 10 or the residence 52.

It should be appreciated that any of the features described herein may be incorporated with the HVAC unit 12, the residential heating and cooling system 50, or other HVAC systems. Additionally, while the features disclosed herein are described in the context of embodiments that directly heat and cool a supply air stream provided to a building or other load, embodiments of the present disclosure may be applicable to other HVAC systems as well. For example, the features described herein may be applied to mechanical cooling systems, free cooling systems, chiller systems, or other heat pump or refrigeration applications.

The description above with reference to FIGS. 1-4 is intended to be illustrative of the context of the present disclosure. The techniques of the present disclosure may be incorporated with any or all of the features described above. In particular, as will be discussed in more detail below, the present disclosure provides techniques that enable an HVAC system to more efficiently direct an air flow. For example, the HVAC system may include a diverter baffle configured to direct the air flow toward a heat exchanger and/or an opening of the HVAC system.

To help illustrate, FIG. 5 is a perspective view of an HVAC system 100 including a discharge section 102 and a blower section 104. The illustrated HVAC system 100 may include embodiments or components of the HVAC unit 12 shown in FIG. 1, embodiments or components of the residential heating and cooling system 50 shown in FIG. 3, a rooftop unit (RTU), or any other suitable HVAC system. For example, the discharge section 102 and the blower section 104 may be sections of an embodiment of the HVAC unit 12. The blower section 104 is configured to receive an air flow from another portion of the HVAC system 100, such as another section of the HVAC unit 12. For example, the blower section 104 may receive an air flow, as indicated by arrow 106, from another section configured to heat and/or cool the air flow, such as a section including an evaporator, a condenser, and/or another type of heat exchanger. The blower section 104 is configured to direct the air into the discharge section 102, which is configured to heat, cool, and/or discharge the air flow received from the blower section 104. For example, the discharge section 102 may discharge the air flow into ductwork or other conduit configured to direct the air flow toward a space conditioned by the HVAC system 100.

The blower section 104 includes a blower 108, such as a supply blower, configured to direct air from the blower section 104 into the discharge section 102, as indicated by arrow 110. In certain embodiments, the blower section 104 and/or the discharge section 102 may include an opening through which the air flow may be directed by the blower 108. For example, a wall or panel separating the discharge section 102 from the blower section 104 may define an opening within which an outlet of the blower 108 is positioned. As illustrated, the blower 108 is a forward curved fan configured to direct air into the discharge section 102. In some embodiments, the blower 108 may be a plenum fan or another type of fan/blower configured to direct air from the blower section 104 to the discharge section 102. Additionally or alternatively, the blower section 104 may include additional blowers, a blower assembly including multiple blowers, and/or other components, such as heat exchangers.

The discharge section 102 includes a diverter baffle 112 disposed within the discharge section 102 and generally adjacent to an outlet of the blower 108. For example, the diverter baffle 112 may be disposed adjacent to the opening in the panel or wall separating the blower section 104 and of the discharge section 102. As air flow is directed into the discharge section 102, as indicated by arrow 110, the diverter baffle 112 is configured to direct the air flow within the discharge section 102, as indicated by arrow 114. For example, arrow 110 may be an axis along which air flow is directed into the discharge section 102 by the blower 108. As shown, the diverter baffle 112 intersects the axis represented by arrow 110 to divert the air flow. In the illustrated embodiment, the diverter baffle 112 is configured to direct the air flow downwardly toward a heater 116, such as heat exchange tubes of the heater 116, disposed below the diverter baffle 112 and within the discharge section 102. In some embodiments, the diverter baffle 112 may be configured to direct the air flow toward a side of the discharge section 102, upwardly within the discharge section 102, or in any other suitable direction. As will be appreciated, the heater 116 is configured to heat the air within the discharge section 102 that is directed by the diverter baffle 112. For example, the heater 116 may be a gas heater or an electric heater. As such, the discharge section 102 is also a heating section, in the illustrated embodiment of the HVAC system 100.

The diverter baffle 112 includes an angled panel 120 and a side panel 122 coupled to one another. It should be noted that the angled panel 120 may be a flat or generally planar panel that is positioned within the discharge section 102 at an angle relative to the axis represented by arrow 110. In other words, the angled panel 120 is positioned within the discharge section 102 at an angle relative to a horizontal plane. As used herein, the term “planar” refers to a geometry that is generally flat without pronounced bends, curves, or other undulations, but also not necessarily constrained by a mathematical or Euclidean plane. The angled panel 120 is configured to direct air output by the blower 108 downwardly toward the heater 116, as indicated by arrow 114 and, as described in greater detail below, is disposed at an oblique angle relative to walls of the discharge section 102. The side panel 122 is also configured to direct air downwardly and toward the heater 116. The side panel 122 in the illustrated embodiment is arranged generally vertically within the discharge section 102. Additionally, in embodiments of the discharge section 102 having a side discharge outlet, the side panel 122 may direct the air toward an opening 130 of a side plate 132 of the discharge section 102. For example, after passing over the heater 116, the air may exit a side of the discharge section 102 via the opening 130, as indicated by arrow 134. The side panel 122 is disposed generally parallel to the side plate 132, such that the side panel 122 is configured to block air flow received from the blower 108 from passing directly toward the side plate 132 without first passing across the heater 116. In certain embodiments, the side panel 122 may be disposed at an angle relative to the side plate 132 and may be configured to block the air flow received from the blower 108 from passing directly toward the side plate 132 and to instead direct the air flow toward the opening 130 and/or across the heater 116.

As such, the diverter baffle 112 may improve an efficiency of the HVAC system 100. For example, the diverter baffle 112 may be configured to guide more air flow directly toward the heater 116 compared to HVAC systems without a diverter baffle. The increase in air flow toward the heater 116 may increase heat transfer between the air flow and a working fluid within the heater 116, thereby increasing a heating capacity of the HVAC system 100. The increase in air flow toward the heater 116 may also decrease the power and/or fuel used by the HVAC system 100 to heat the air flow, may enable more efficient air flow through the HVAC system 100, may reduce local hot spots within the HVAC system 100, or a combination thereof.

Additionally, the diverter baffle 112 may be configured to more efficiently direct air flow from the blower 108 and toward an outlet of the discharge section 102, such as the opening 130. For example, in embodiments of the discharge section 102 with or without the heater 116, the diverter baffle 112 may be configured to more effectively direct the air flow toward an outlet of the discharge section 102 compared to HVAC systems without a diverter baffle. As such, the diverter baffle 112 may enable a reduction in power utilized by the blower 108 to direct the air flow through the discharge section 102 and may effectuate an improved efficiency of the blower 108. For example, the diverter baffle 112 may effectuate improved and/or more efficient air flow through discharge section 102 and/or other sections of the HVAC system 100, such that the power consumed by the blower 108 and/or by the HVAC system 100 generally, is reduced by two percent to three percent. Additionally or alternatively, the diverter baffle 112 may improve air flow through the HVAC system by about eight percent.

FIG. 6 is a perspective view of another embodiment of the discharge section 102 and the blower section 104 of the HVAC system 100. As illustrated, the discharge section 102 includes a base plate 140 disposed below the heater 116. The base plate 140 includes an opening 142 configured to discharge air flow from the discharge section 102, as indicated by arrow 144. For example, the diverter baffle 112 may direct air flow received from the blower 108 downwardly toward both the heater 116 and the opening 142, as indicated by arrows 110 and 114, for discharge from the discharge section 102. For example, the opening 142 may fluidly couple the discharge section 102 with ductwork or other conduit configured to direct air flow from the HVAC system 100 to a space conditioned by the HVAC system 100. In certain embodiments, the heater 116 may be omitted from the discharge section 102, such that the diverter baffle 112 may direct the air flow received from the blower 108 directly toward the opening 142. In some embodiments, the discharge section 102 may include both the opening 130 of FIG. 5 and the opening 142 of FIG. 6.

FIG. 7 is a side view of an embodiment of the discharge section 102 and the blower section 104 of the HVAC system 100. As described above, the blower 108 is configured to direct an air flow received from another portion of the HVAC system 100, as indicated by arrow 106, from the blower section 104 and into the discharge section 102, as indicated by arrow 110. The diverter baffle 112 is configured to direct air flow toward the heater 116 and toward the opening 130 and/or the opening 142, as indicated by arrow 114.

The discharge section 102 includes a wall 150 and a wall 152 disposed opposite and spaced apart from one another. The wall 150 separates the discharge section 102 and the blower section 104. As illustrated, the blower 108 is mounted to the wall 150. The wall 150 includes/defines an opening 154 configured to enable discharge of air flow into the discharge section 102 by the blower 108. For example, the opening 154 may be generally the same width as an opening 156 of the blower 108. In some embodiments, the arrow 110 may represent a central axis of the opening 154 and/or the opening 156, such that air flow directed through the opening 154 and the opening 156 flows along the central axis and towards the angled panel 120 of the diverter baffle 112. The central axis of the opening 154 and/or the opening 156 may intersect the angled panel 120 of the diverter baffle 112. In other words, the angled panel 120 is positioned within a flow path of the air discharge by the blower 108 into the discharge section 102. Additionally, the side panel 122 may extend in a common direction and/or generally parallel to the central axis of the opening 154. In certain embodiments, the wall 152 may be a blast wall against which the air flow directed into the discharge section 102 by the blower 108 may impinge.

Each of the angled panel 120 and the side panel 122 of the diverter baffle 112 extend from the wall 150 to the wall 152. Additionally, the angled panel 120 is disposed at angle 158 relative to the wall 150. In other words, the angle 158 is measured with reference to a generally vertical plane. The angled panel 120 disposed at the angle 158 enables the diverter baffle 112 to direct the air flow received from the blower 108 toward the heater 116 and toward the opening 130 and/or the opening 142. The angle 158 may be any oblique angle that enables the diverter baffle 112 to direct the air flow toward the heater 116 and toward the opening 130 and/or the opening 142. For example, the angle 158 may be any angle between one degree and eighty-nine degrees, between five degrees and eighty-five degrees, between fifteen degrees and seventy-five degrees, between forty-five degrees and seventy-five degrees, between twenty-five degrees and sixty-five degrees, between thirty-five degrees and fifty-five degrees, or any other suitable angle.

As illustrated, the angle 158 between the angled panel 120 and the wall 150 is constant, such that the angled panel 120 is generally planar. In certain embodiments, the angle 158 may vary, such that the angled panel 120 is curved. For example, the angle 158 may increase as the angled panel 120 extends further from the wall 150, and the angled panel 120 may curve downwardly toward the base plate 140. In certain embodiments, the angle 158 may be seventy-five degrees at a first end 161 of the angled panel 120 adjacent to the wall 150 and one hundred five degrees at a second end 162 of the angled panel 120 adjacent to the wall 152. As described in greater detail below, the first end 161 is offset from the opening 130. Additionally, the second end 162 may be aligned or substantially aligned with the opening 130 such that a portion of the air flow received through the opening may contact the second end 162.

As described above, the diverter baffle 112 is configured to divert the air flow received from the blower 108, as indicated by arrow 110, toward the heater 116 and toward the opening 130 and/or the opening 142, as indicated by arrow 114. An angle 159 between arrow 110 and arrow 114 may be approximately ninety degrees, such that the air flow is directed downwardly by the diverter baffle 112 at an approximately right angle. In certain embodiments, the angle 159 may be between eighty-five degrees and ninety degrees, between seventy-five degrees and one hundred five degrees, or between sixty degrees and one hundred twenty degrees.

Further, the diverter baffle 112 may substantially block the air flow from traveling into an area 160 on an opposite side of the diverter baffle 112 relative to the heater 116 and the openings 130 and 142, as well as to other portions of the discharge section 102. For example, the diverter baffle 112 may substantially reduce recirculation of the air into the area 160 and/or into other portions of the discharge section 102. In this manner, the diverter baffle 112 improves air flow efficiency within the discharge section 102 by more acutely directing the air flow toward a discharge opening, such as opening 130 and/or 142, of the discharge section 102. Additionally, the diverter baffle 112 effectuates an improved efficiency of the blower 108 by diverting and directing the air flow received from the blower 108.

FIG. 8 is a side view of an embodiment of the discharge section 102 and the blower section 104 of the HVAC system 100. As described above, the angled panel 120 and the side panel 122 of the diverter baffle 112 are configured to direct air flow received from the blower 108 toward the heater 116 and toward the opening 130 and/or the opening 142, as indicated by arrow 114. As illustrated, the arrow 114 includes a first portion 170 on an opposite side of the side panel 122 and a second portion 172 below the diverter baffle 112. The air flow directed by the angled panel 120 and the side panel 122 may first be directed downwardly toward the heater 116 and toward the opening 130 and/or the opening 142, as indicated by the first portion 170. After passing by the side panel 122, the air flow may disperse beyond the diverter baffle 112 and along the discharge section 102, such as over the heater 116 and toward the side plate 132, as indicated by the second portion 172. As such, the side panel 122 may enable the diverter baffle 112 to direct the air flow toward the heater 116 and toward the opening 130 and/or the opening 142 prior to dispersion along the discharge section 102.

As illustrated, the diverter baffle 112 extends between the wall 150 and the wall 152 and includes a height 174 generally parallel to the wall 150 and the wall 152 and a length 176 generally parallel to the base plate 140. Additionally, the opening 154 of the wall 150 and the opening 156 of the blower 108 extend a height 178 along the wall 150. Further, the diverter baffle 112 is coupled to the wall 150 at a location that is offset from the blower 108, such as at the first end 161, by an offset distance 180. As illustrated, the height 174 of the diverter baffle 112 overlaps a majority of the height 178, such that the angled panel 120 of the diverter baffle 112 is configured to intersect and divert a majority of the air flow exiting the blower 108. In certain embodiments, the angled panel 120 may intersect and divert an entire amount of air flow exiting the blower 108, half an amount of the air flow exiting the blower 108, or less than half an amount of the air flow exiting the blower 108. The offset distance 180 of the attachment point of diverter baffle 112 from the blower 108 enables the diverter baffle 112 to block air flow exiting the blower 108 from circulating into the area 160, such as the area above the diverter baffle 112. The length 176 may be equal to a length of the base plate 140 such that the diverter baffle extends the entire length of the discharge section 102 between the wall 150 and the wall 152.

FIG. 9 is a top view of an embodiment of the discharge section 102 and the blower section 104 of the HVAC system 100. The diverter baffle 112 extends a width 190 along the wall 150, within the discharge section 102, and transverse to a direction of the air flow, as indicated by arrow 110. The blower 108, such as an outlet of the blower 108, extends a width 192 along the wall 150, within the blower section 104, and transverse to a direction of the air flow, as indicated by arrow 110. As illustrated, the width 190 of the diverter baffle 112 is greater than the width 192 of the blower 108, which enables the diverter baffle 112 to divert and direct a majority of air flow received from the blower 108. In some embodiments, the width 190 of the diverter baffle 112 may be equal to the width 192 of the blower 108 to enable the diverter baffle 112 to divert and direct a majority of air flow received from the blower 108. Alternatively, the width 190 of the diverter baffle 112 may be equal to a width 194 of the wall 150 to enable the diverter baffle 112 to divert and direct a majority of air flow received from the blower 108. In some embodiments, the width 194 may be a width of the base plate 140.

FIG. 10 is a perspective view of an embodiment of the discharge section 102 and the blower section 104 of the HVAC system 100. As illustrated, the blower section 104 includes a blower assembly 200 having two blowers 202, such as supply blowers, operationally coupled to one another via a common shaft 204. Each blower 202 may be coupled to the wall 150 that separates the discharge section 102 from the blower section 104. In certain embodiments, the blower section 104 and/or the discharge section 102 may include two openings through which the air flow may be directed by the blowers 202. For example, the wall 150 may have two openings. An outlet of each blower 202 may be positioned within a respective opening such that each blower 202 may direct air flow through the respective opening and into the discharge section 102. In some embodiments, the blower assembly 200 may be coupled to a single opening of the wall 150 such that the blowers 202 are configured to direct air flow through the single opening.

Additionally, the common shaft 204 may be coupled to a motor of the HVAC system 100 and may be configured to rotate to cause the blowers 202 to direct air from the blower section 104 and into the discharge section 102. For example, after receiving the air flow from another portion of the HVAC system, as indicated by arrow 106, the blower assembly 200 may direct the air flow into the discharge section 102, as indicated by arrows 110. The diverter baffle 112 is configured to divert and direct the air flow received from the blowers 202 toward the heater 116 and toward the opening 130 and/or an alternate opening disposed below the heater 116. The air flow may then exit the opening 130, as indicated by arrow 134, or may exit the alternate opening below the heater 116. As such, the diverter baffle 112 may effectuate an improved efficiency of the blower assembly 200 and the HVAC system 100 generally by diverting and directing the air flow received from the blowers 202.

In certain embodiments, the HVAC system 100 may include two or more diverter baffles 112. For example, a first blower 202 may direct air through a first opening of the wall 150, and a first diverter baffle 112 may divert and direct the air flow received from the first blower 202 toward the heater 116 and toward the opening 130 and/or an alternate opening disposed below the heater 116. A second blower 202 may direct air through a second opening of the wall 150, and a second diverter baffle 112 may divert and direct the air flow received from the second blower 202 toward the heater 116 and toward the opening 130 and/or an alternate opening disposed below the heater 116. The two diverter baffles 112 may be arranged adjacent to each other within the discharge section 102 and positioned generally similarly to the illustrated diverter baffle 112.

In some embodiments, the blower assembly 200 may include three or more blowers 202 configured to direct air flow into the discharge section 102. Each of the blowers 202 may be coupled to a respective opening of the discharge section 102, such as an opening within the wall 150, or multiple blowers 202 may be coupled to a single opening. Further, the HVAC system 100 may include a respective diverter baffle 112 for each of the three or more blowers 202.

FIG. 11 is a top view of an embodiment of the discharge section 102 and the blower section 104 of the HVAC system 100. The blower assembly 200 extends a width 210 along the wall 150, within the blower section 104, and transverse to a direction of the air flow, as indicated by arrows 110. The width 210 includes a respective width 212 of each blower 202, such as a width of an outlet of each blower 202, and a width 214 of the common shaft 204 extending between the two blowers 202. Additionally, the diverter baffle 112 extends the width 190 along the wall 150 and within the discharge section 102. As illustrated, the width 190 of the diverter baffle 112 is greater than the width 210 of the blower assembly 200, which enables the diverter baffle 112 to divert and direct a majority of the air flow received from the blower assembly 200, as indicated by arrows 110. For example, the width 210 of the blower assembly 200 may be generally equal to a width of a single opening through which the air flow may directed into the discharge section 102 by the blower assembly 200. In certain embodiments, each blower 202 may direct air flow through a respective opening of the wall 150 having a width generally equal to the width 212. In some embodiments, the width 190 of the diverter baffle 112 may be equal to the width 210 of the blower assembly 200 to enable the diverter baffle 112 to divert and direct a majority of the air flow received from the blower assembly 200. Alternatively, the width 190 of the diverter baffle may be equal to the width 194 of the wall 150 to enable the diverter baffle 112 to divert and direct a majority of the air flow received from the blower assembly 200.

Accordingly, the present disclosure provides systems including a diverter baffle configured to divert an air flow, such as the air flow output by a blower of the HVAC system. The diverter baffle enables the HVAC system to efficiently direct the air flow through a heating section and/or a discharge section. For example, the diverter baffle may direct the air flow from the blower toward a heat exchanger disposed within a heating section and/or toward an opening configured to discharge the air flow from a discharge section. In so doing, the diverter baffle also improves operation of the blower. For example, the inclusion of the diverter baffle may enable the blower to utilize less power to achieve a desired level of air flow. As such, the systems described herein improve air flow through the HVAC system and increase efficient operation of the HVAC system.

The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function]. . . ” or “step for [perform]ing [a function] . . . ”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).

The specific embodiments described above have been shown by way of example, and it should be understood that these embodiments may be susceptible to various modifications and alternative forms. It should be further understood that the claims are not intended to be limited to the particular forms disclosed, but rather to cover all modifications, equivalents, and alternatives falling within the spirit and scope of this disclosure.

DIVERTER BAFFLE FOR A BLOWER

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CROSS REFERENCE TO RELATED APPLICATIONS

Provisional Applications (1)