Patent Application
20220357072
Exemplary embodiments of the disclosure relate generally to an air conditioning system, and more particularly, to an integrated diffuser grille suitable for use with a fan of an air conditioning system.
Conventional air conditioning units usually include an indoor unit for evaporation and heat absorption and an outdoor unit for condensation and heat dissipation. Such outdoor units or condensing units include grilles positioned over each fan to prevent foreign objects from being introduced into the flow path of the fan and serve as finger protection without impeding the fan performance. The grilles present in existing outdoor units or condensing units are typically wire grilles (made of metal). While existing wire grilles are suitable for their intended purpose, it is desirable to provide an alternate composite grille or guard without impeding the operational efficiency of the system or the compliancy with the UL standards required for such part.
Disclosed is an integrated diffuser grille for a coil unit including a hub, a stack diffuser wall, a plurality of radial spokes extending between the hub and the stack diffuser wall, and a plurality of partial spokes extending inwardly from the stack diffuser wall. A radial length of the partial spokes is less than a radial length of the spokes. A plurality of circumferential elements is connected to the plurality of radial spokes between the hub and the stack diffuser wall. At least one circumferential element is connected to the plurality of partial spokes and at least one circumferential element has a non-uniform configuration about a circumference of the plurality of circumferential elements. A cross-section of the plurality of radial spokes has an airfoil-shape and at least one of a spoke pitch angle, camber angle, and chord of the airfoil-shape varies over a radial length of the plurality of spokes.
In addition to one or more of the features described above, or as an alternative, in further embodiments the plurality of radial spokes and the plurality of partial spokes are configured to straighten an air flow as it flow across the plurality of radial spokes and the plurality of partial spokes.
In addition to one or more of the features described above, or as an alternative, in further embodiments a stacking line defined by a mid-chord of the airfoil-shape over the radial length of at least one of the plurality of radial spokes is a straight line.
In addition to one or more of the features described above, or as an alternative, in further embodiments each of the plurality of radial spokes includes a radially inner portion adjacent to the hub, a radially outer portion adjacent to the stack diffuser wall, and a radially middle portion disposed between the radially inner portion and the radially outer portion.
In addition to one or more of the features described above, or as an alternative, in further embodiments the radially inner portion extends from 0% to about 20% of the radial length, the radially middle portion extends from about 20% to about 70% of the radial length, and the radially outer portion extends from about 70% to 100% of the radial length.
In addition to one or more of the features described above, or as an alternative, in further embodiments the radially inner portion of at least one of the plurality of radial spokes has at least one of a spoke pitch angle that increases from about 45-55 degrees to about 60-65 degrees relative to a circumferential direction, a camber angle that decreases from about 15-25 degrees to about 0-5 degrees, and a chord that decreases from about 80%-85% to about 70%-75% relative to the chord at a tip section.
In addition to one or more of the features described above, or as an alternative, in further embodiments the radially outer portion of at least one of the plurality of radial spokes has at least one of a spoke pitch angle that decreases from about 70-80 degrees to about 30-50 degrees relative to a circumferential direction, a camber angle that increases from about 0-5 degrees to about 15-25 degrees, and a chord that increases from about 65%-70% to 100% relative to the chord at a tip section.
In addition to one or more of the features described above, or as an alternative, in further embodiments the radially middle portion of at least one of the plurality of radial spokes has at least one of a spoke pitch angle that increases from about 60-65 degrees to about 70-80 degrees relative to a circumferential direction, a camber angle that is constant between about 0-5 degrees, and a chord that decreases from about 70%-75% to about 65%-70% relative to the chord at a tip section.
In addition to one or more of the features described above, or as an alternative, in further embodiments each of the plurality of partial spokes has an airfoil-shape and a configuration of the plurality of partial spokes is substantially identical to a configuration of the plurality of radial spokes at a same radial position.
In addition to one or more of the features described above, or as an alternative, in further embodiments the hub, stack diffuser wall, plurality of radial spokes, plurality of partial spokes, and plurality of circumferential elements are integrally formed as a single unitary structure, the single unitary structure being formed from a non-metal material.
In addition to one or more of the features described above, or as an alternative, in further embodiments the single unitary structure is formed from a plastic material.
In addition to one or more of the features described above, or as an alternative, in further embodiments the plurality of circumferential elements have an upstream side and a downstream side, and the upstream side of the at least one circumferential element has a non-uniform contour.
In addition to one or more of the features described above, or as an alternative, in further embodiments a depth increases in a direction toward the upstream side of the at least one circumferential element at a location adjacent to an interface with each of the plurality of radial spokes.
In addition to one or more of the features described above, or as an alternative, in further embodiments the radial length of the plurality of partial spokes is less than or equal to about 40% of the radial length of the plurality of radial spokes.
In addition to one or more of the features described above, or as an alternative, in further embodiments comprising a plurality of features integrally formed with the stack diffuser wall.
In addition to one or more of the features described above, or as an alternative, in further embodiments the plurality of features are radially aligned with the plurality of radial spokes and the plurality of partial spokes.
In addition to one or more of the features described above, or as an alternative, in further embodiments the plurality of features are arranged in groups, the groups being spaced about a periphery of the outer wall.
In addition to one or more of the features described above, or as an alternative, in further embodiments the integrated diffuser grille is part of a top cover assembly of an air chiller unit of an air conditioning system.
In addition to one or more of the features described above, or as an alternative, in further embodiments the top cover assembly further comprises a fan assembly, the integrated diffuser grille being positioned in overlapping arrangement with the fan assembly to restrict access to the fan assembly.
In addition to one or more of the features described above, or as an alternative, in further embodiments the integrated diffuser grille is positioned downstream of the fan assembly relative to an airflow through the fan assembly.
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
The base pan 22 supports the remainder of the components of the coil unit 20. As shown, a heat exchanger assembly 24 is arranged within the base pan 22. In the illustrated, non-limiting embodiment, the heat exchanger assembly 24 includes two heat exchanger coils oriented in a V or A-shape. However, a heat exchanger assembly having another shape, such as a W-shape for example, is also contemplated herein. Further, embodiments where the heat exchanger assembly 24 wraps about one, two, three, or four sides and/or one or more corners of the footprint of the base pan 22 between two headers are also within the scope of the disclosure. However, in such embodiments, the planform of the heat exchanger assembly 24 need not match the planform of the base pan 22. A compressor 26, fluidly coupled to the heat exchanger 24, is positioned within the interior of the heat exchanger 24 and is configured to pump refrigerant through a vapor compression cycle.
The base pan 22 forms a lower portion of the housing, and a top cover assembly 30 forms an upper portion of the housing. Along the lateral perimeter, the housing may include one or more louvered panels 28, corner posts (not shown), or another structural member to connect the base pan 22 and the top cover assembly 30. The top cover assembly 30 includes at least one fan assembly 32 and a grille or fan guard 34 associated with each fan assembly 32. It will be appreciated that the grilles or fan guards 34 illustrated in
With reference now to
With reference now to
As best shown in
In embodiments where the fan assembly 32 is configured as an axial flow fan, the airflow A moving through the fan assembly 32 towards the grille 34 generally has both an axial component, a radial component, and a tangential component. In an embodiment, the plurality of spokes 54 are configured as outlet guide vanes. Accordingly, the configuration of the radial spokes 54 may be selected to straighten the flow exiting from the fan assembly 32, thereby transforming swirl kinetic energy in the airflow A into static pressure rises across the spokes 54. In such embodiments, the spokes 54 may include lean or sweep in the circumferential or axial directions. Parameters of the spokes 54 that may be controlled to diffuse or straighten the air flow A include, but are not limited to spoke pitch angle, chamber angle, and chord.
The configuration of each spoke 54 may vary over the radial length or span of the spoke 54 to compensate for the conditions of the airflow A in that region. For example, each spoke 54 may include a radially inner portion extending from the hub (0%) to about 20% of the span, a radially middle portion extending between about 20% of the span and about 70% of the span, and a radially outer portion extending from about 70% to 100% of the span. An example of a cross-section of a radially inner portion of a spoke 54 is shown in
The radially middle portion of at least one of the spokes 54, as shown in
The air flow A output from the fan rotor 38 may have a high swirl adjacent to the distal ends 44 of the fan blades 40. To compensate for this flow, the radially outer portion of one or more of the spokes 54, see
In the illustrated, non-limiting embodiment, the grille 34 additionally includes a plurality of partial spokes 56 extending inwardly from the outer wall 52 and arranged between pairs of adjacent spokes 54. Although the partial spokes 56 are shown equidistantly spaced between each pair of adjacent spokes 54, embodiments where one or more of the partial spokes 56 is arranged at a non-central location between a pair of spokes 54 are also contemplated herein. A radial length of the partial spokes 56 is less than a radial length of the spokes 54. In an embodiment, the radial length of the partial spokes 56 is less than 50% of the radial length of the spokes 54, and further may be less than 40%, less than 30%, or even less than 20% of the radial length of the spokes 54.
Because the airflow A provided to partial spokes 56 has the same flow conditions as the flow provided to a corresponding portion of the spokes 54, in an embodiment, a configuration of the partial spokes 56 is substantially identical to a configuration of the spokes at the same radial location (see
With reference again to
The grille 34 may additionally include one or more elements 62 extending circumferentially about the hub 50, between the hub 50 and the outer wall 52. In the illustrated, non-limiting embodiment, the grille 34 includes a plurality of concentrically mounted circumferential elements 62 spaced equidistantly from one another and between the hub 50 and the outer wall 52. However, embodiments where the circumferential elements 62 are not equidistantly spaced or where a center of one or more of the circumferential elements 62 is offset from the fan axis X are also within the scope of the disclosure. A plurality of openings 64 are defined between adjacent circumferential elements 62, radial spokes 54, and partial spokes 56. In an embodiment, the size of the plurality of openings 64 is selected to prevent the introduction of foreign objects or a finger into the fan assembly 32 via the grille 34. However, it should be noted that the size of the openings 64 defined at least partially by the partial spokes 56 are smaller than the openings 64 defined between adjacent radial spokes 54 and circumferential elements 62.
As shown, each of the circumferential elements 62 may be connected to each of the plurality of radial spokes 54. Further, at least a portion of the circumferential elements 62 may be configured to overlap with the partial spokes 56 and may be similarly connected to each of the partial spokes 56. In an embodiment, the hub 50, stack diffuser outer wall 52, spokes 54, partial spokes 56, and circumferential elements 62 are integrally formed as a single unitary component. In such embodiments, the grille 34 may be manufactured via any suitable process, including but not limited to injection molding or additive manufacturing for example. In an embodiment, the grille 34 is formed from a non-metal material, such as plastic or composite for example. By using a plastic material, the potential for degradation, such as the formation of rust as a result of exposure to the elements (for example rain) is eliminated. However, embodiments where the grille 34 is formed from a metal material are also within the scope of the disclosure.
In an embodiment, a configuration of one or more of the circumferential elements 62 varies or is non-uniform about its circumference. For example, as best shown in
As illustrated and described above, the grille 34 may be suitable for use with a coil unit 20. In certain instances, the grille 34 may be configured to satisfy all UL compliance requirements for outdoor fan grilles. For example, the grille may be formed from a UL approved material, satisfy UL finger protection requirements, and may support a structural load of 200 pounds over a 6 inches diameter circle. Further, the performance of the grille 34 may be on par with (or better than) existing wire grilles and may provide a suitable replacement option for existing systems without negatively impacting the aerodynamic performance of the fan assembly or overall system efficiency.
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. 63/185,117 filed May 6, 2021, the disclosure of which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63185117 | May 2021 | US |
