Patent Application
20230349589
Exemplary embodiments pertain to the art of heating, ventilation and air conditioning (HVAC) systems.
HVAC systems, such as, for example, air handlers or furnaces, include components contained in an outer jacket or casing. It is necessary to provide access through the jacket for connections such as vent and combustion air piping, electrical power and controls, condensate trap, and other auxiliary component connections. The jacket provides resistance to air leakage, as air leakage reduces efficiency of the HVAC system or may affect combustion performance. Such access is typically provided by knockout features provided in various locations in the jacket. Such knockout features (often referred to as ‘slugs’) that are formed as removable segments in the jacket, however, are not replaceable into the jacket once removed, and thus result in significant air leakage in the event that a component connection is no longer needed, or a connection routing is changed so the knockout is no longer needed.
In one embodiment, a removable plug for a heating ventilation and air conditioning (HVAC) system includes a main body extending from a plug central axis, and a plug lip defining an outer perimeter of the plug. A radially outer surface is located between the main body and the plug lip. One or more plug retention features extend radially outwardly from the radially outer surface. The one or more plug retention features define an interference fit with a jacket opening of the HVAC system when the plug is installed to the jacket opening.
Additionally or alternatively, in this or other embodiments the plug is formed from a metal material.
Additionally or alternatively, in this or other embodiments a plug recess connects the main body to the plug lip. The plug recess includes the radially outer surface extending from the plug lip, a radially inner surface extending from the main body, and a recess base connecting the radially inner surface and the radially outer surface. The recess base is offset from the main body in an axial direction relative to the plug central axis.
Additionally or alternatively, in this or other embodiments each of the radially inner surface and the radially outer surface extend at a non-zero angle relative to the plug central axis.
Additionally or alternatively, in this or other embodiments an inner surface angle of the radially inner surface is in the range of 10-20 degrees.
Additionally or alternatively, in this or other embodiments an outer surface angle of the radially outer surface is in the range of 2-5 degrees.
Additionally or alternatively, in this or other embodiments the plug lip extends radially outwardly at a lip angle relative to the main body in the range of 5 to 10 degrees.
Additionally or alternatively, in this or other embodiments the plug is one of circular, oval, rectangular or rounded rectangular in shape.
Additionally or alternatively, in this or other embodiments the one or more plug retention features are one or more dimples.
Additionally or alternatively, in this or other embodiments a dimple of the one or more dimples has a curvilinear cross-sectional shape.
Additionally or alternatively, in this or other embodiments the main body is axially offset from the plug lip relative to the plug central axis.
Additionally or alternatively, in this or other embodiments the one or more plug retention features are one or more fasteners installed through the radially outer surface.
In another embodiment, a heating, ventilation and air conditioning (HVAC) system includes one or more HVAC system components, and a jacket enclosing the one or more HVAC system components. The jacket includes a jacket outer surface, one or more jacket openings formed in the jacket outer surface, and a removable plug installed in a jacket opening of the one or more jacket openings. The plug includes a main body extending from a plug central axis, a plug lip defining an outer perimeter of the plug, a radially outer surface disposed between the main body and the plug lip, and one or more plug retention features extending radially outwardly from the radially outer surface. The one or more retention features define an interference fit with a jacket opening of the HVAC system when the plug is installed to the jacket opening.
Additionally or alternatively, in this or other embodiments the plug is formed from a metal material.
Additionally or alternatively, in this or other embodiments a plug recess connects the main body to the plug lip. The plug recess includes the radially outer surface extending from the plug lip, a radially inner surface extending from the main body, and a recess base connecting the radially inner surface and the radially outer surface. The recess base is offset from the main body in an axial direction relative to the plug central axis.
Additionally or alternatively, in this or other embodiments each of the radially inner surface and the radially outer surface extend at a non-zero angle relative to the plug central axis.
Additionally or alternatively, in this or other embodiments the plug lip extends radially outwardly at a lip angle relative to the main body in the range of 5 to 10 degrees.
Additionally or alternatively, in this or other embodiments the one or more plug retention features are one or more dimples.
Additionally or alternatively, in this or other embodiments the main body is axially offset from the plug lip relative to the plug central axis.
Additionally or alternatively, in this or other embodiments the one or more plug retention features are one or more fasteners installed through the radially outer surface.
The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
Referring now to
While a plurality of such jacket openings 16 are formed in the jacket 14, not all of the jacket openings 16 may be utilized at any one time, depending on factors such as an orientation of the furnace 10 and jacket 14 at an installation site, components connected to the furnace 10 and access locations needed into the jacket 14 for a particular furnace 10 installation and configuration. It should be appreciated that a single jacket 14 may be utilized for multiple furnace configurations.
Plugs 18 are installed to the unused jacket openings 16 of the jacket 14. The plugs 18 are formed from a heat resistant material (e.g., metal, etc.) and are configured to resist deformation and warpage. The plugs 18 are fitted to the jacket openings 16 so the plugs 18 may be retained in place for an entire service life of the furnace 10, for example, twenty (20) years or more, and for transport of the furnace 10 to the installation location. The plugs 18 are configured to be easy to remove from and install to the jacket 14, fit closely to the jacket openings 16 to resist air leakage through the jacket 14, and are relatively low cost. The plugs 18 are configured to be installed in a variety of jacket opening 16 sizes and shapes. For example, some plugs 18, may be installed in a circular jacket opening 16 (e.g., which may have a 3 inch diameter. It should be appreciated that the plugs 18 may be configured to fit any jacket opening 16, such as, for example, 1.75 inch diameter, 0.875 inch diameter, 0.75 inch diameter or 0.50 inch diameter jacket openings 16. Further, the plugs 18 may be shaped and sized to be installed in rectangular jacket openings 16 and/or jacket openings 16 which are rectangular with rounded corners. For example, in one embodiment the plug 18 is configured for installation into a rectangular opening which is 4 inches by 2.5 inches and having rounded corners. It should be appreciated that the plugs 18 may be configured to fit any jacket opening 16 with any associated geometry.
In some embodiments, the jacket 14 is formed from a metal material, such as sheet steel which may be in the range of 0.03 to 0.035 inches thick. The plugs 18 may be formed from the same material, or alternatively from a different metal material than the jacket 14. For example, in some embodiments the plugs 18 may be formed from an aluminum material or other metal material having a thickness in the range of 0.016 to 0.020 inches. One skilled in the art, however, will readily appreciate that the plugs 18 may be formed having other material thicknesses.
Referring now to
The plug recess 28 is illustrated in more detail in the partial cross-sectional view of
The plug 18 includes one or more dimples 44 formed in the plug 18, and located on the outer sloping portion 38. The dimple 44 extends radially outwardly from the outer sloping portion 38, and when the plug 18 is installed to the jacket 14, while the plug lip 24 abuts an outer jacket surface 46 define on an outside of the jacket 14, the dimple 44 engages an inner jacket surface 48 on an inside of the jacket 14. In some embodiments, the dimple 44 is curvilinear in shape. The dimple 44 aids in retention of the plug 18 in the jacket opening 16. The size, number, and location of the dimples 44 may vary depending on the size and shape of the jacket opening 16 and plug 18, and may also be varied based on the retention properties desired. For example, as shown in
In another embodiment, illustrated in
The plug 18 configurations disclosed herein are easy to install and improve leakage performance of the jacket 14 due to tight and leak-resistant fit and retention of the plug 18 to the jacket openings 16. Further, the metal construction improves heat resistance of the plugs 18, and prevents warpage, melting or burning of the plug.
The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.
While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.
This application claims the benefit of U.S. Provisional Application No. 63/336,406 filed Apr. 29, 2022, the disclosure of which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63336406 | Apr 2022 | US |
