Patent Application
20230003418
The present invention relates generally to a miniaturized air handler assembly. More so, the present invention relates to an air handler that sits on a drain pan, and intakes air from opposing coil panels, or a panel formed from a plurality of coils arranged in parallel, such that the air flows across the coils that carry a cooling fluid, thereby cooling the air; and further draws in the cooled air with a fan to disperse through an HVAC duct or plenum; whereby the intake of air from opposing panels enables the miniaturization of the air handler.
The following background information may present examples of specific aspects of the prior art (e.g., without limitation, approaches, facts, or common wisdom) that, while expected to be helpful to further educate the reader as to additional aspects of the prior art, is not to be construed as limiting the present invention, or any embodiments thereof, to anything stated or implied therein or inferred thereupon.
Often, buildings and enclosed structures are cooled using chilled water that is circulated through the building. In many instances, the chiller utilizes water conduits to carry the chilled water through the building. The water conduits are routed to air handlers located on individual floors and sections of the building. The air handlers push or pull air past cooling coils through which the chilled water flows. Heat is removed from the air by the cooling coils and the chilled water within the cooling coils. During this cycle, the chilled water warms up and is returned via water conduits to one or more chillers for cooling. The chillers controllably adjust the temperature of the chilled water output for the air handlers.
As variables such as temperature and humidity vary, multiple chillers, pumps, or cooling towers may need to be brought online or taken offline to serve the varying cooling needs of the building. It can be problematic to efficiently control a chiller plant for a building. Due in part to the varying nature of a building environment (e.g., occupancy, etc.), the varying nature of weather (e.g., temperature, humidity, etc.), and the varying nature of equipment performance.
Typically, the capacity of an air conditioning unit is directly related the surface area of the cooling coil. The higher the BTU removal capacity of the cooling coil, the larger the cooling coil needs to be which requires a larger cabinet to house the coil as well as a larger space to fit the entire air conditioning unit. Since space is at a premium in most building and mechanical rooms, a substantial amount of room is needed to fit conventional cooling coil designs in these air conditioning systems.
Also due to the size of such air conditioning units, it can be difficult to change and maintain. The capacity of the air conditioning unit is directly related the surface area of the cooling coil. The higher the BTU removal capacity of the cooling coil, the larger the cooling coils need to be. This requires a larger cabinet to house the cooling coils, as well as a larger space to fit the entire air conditioning unit.
With space being at a premium in building and mechanical rooms, a substantial amount of space is required to fit conventional cooling coil designs in such air conditioning units. Also due to the size of these air conditioning units, it is often difficult to change and maintain. Further, the higher capacity of an air conditioning unit in BTU's the larger cooling coil section needs to be and with a single direction airflow unit this requires larger rooms and coil pull areas to service the cooling coil or change if necessary.
Other proposals have involved air conditioning units that have smaller profiles. The problem with these units is that they do not intake air from multiple sides of the unit. Also, they allow excess condensate to fall into components of the air handler, causing flooding. Even though the above cited air conditioning units meet some of the needs of the market, a miniaturized air handler assembly that includes an air handler that sits on a drain pan, and intakes air from opposing coil panels across coils that carry a cooling fluid, thereby cooling the air; and further draws in the cooled air with a fan to disperse through an HVAC duct or plenum; whereby the intake of air through opposing panels, or a wall of coils, enables the miniaturization of the air handler, is still desired.
Illustrative embodiments of the disclosure are generally directed to a miniaturized air handler assembly. The miniaturized air handler assembly provides a unique air handler that resides completely on a drain pan. The air handler comprises multiple panels forming an enclosed chamber with a central region. Two of the opposing panels are apertured, or coil assemblies, so as to enable passage of air from outside to the enclosed chamber. Multiple cooling coils, which carry a cooling fluid, are disposed in a generally parallel relationship, and on the inner side, of the coil panels. A blower forces high velocity air through the two opposing coil panels, and across the cooling coils. This serves to cool the air. The condensate that inherently forms on the cooling coils falls into the drain pan; and thereby does not travel into the subsequent components of the air handler.
From the cooling coils, the cooled air flows to the central region of the air handler. A fan at the top of the air handler sucks the cooled air from an outlet opening that forms in a top panel for dispersing through a duct or plenum. The air handler is unique in that, the intake of air from opposing panels enables the miniaturization of the air handler. The air handler is also unique in that the condensate never reaches the fan or central region of the air handler, because the high velocity airflow causes condensate to drip, or fall, off the surface of the cooling coils, and into the drain pan. In essence, all the air and the condensate enter into the central region. It is known in the art that in prior art units, such condensate flooded the air handler if the condensate blew off the coil missing the drain pan. This is known in the industry as carry over.
In one aspect, a miniaturized air handler assembly, comprises:
In another aspect, the enclosed chamber defines a cubicle or a rectangular shape. However, the shape can also be any polygon with at least two cooling coils with flow in opposing direction into the center of the chamber.
In another aspect, at least two of the panels are solid. In other embodiments, the chamber can be created by any number of cooling coils. For example, four cooling coils can be joined at the corners to create a chamber, whereby no solid panel would be necessary other than connection pieces on the corner to prevent air infiltration.
In another aspect, the panels are fabricated from metal.
In another aspect, the cooling coils are arranged vertically in relation to the coil panels.
In another aspect, the cooling coils are arranged horizontally in relation to the coil panels.
In another aspect, the cooling coils are evaporator cooling coils.
In another aspect, the cooling coils include six rows of coils that about a total of one hundred-eighty tubes and two hundred-forty vertical fins.
In another aspect, the assembly further comprises one or more blowers operable to blow the air at a high velocity across the cooling coils and into the enclosed chamber, whereby the air is cooled, whereby the air accumulates in the central region of the enclosed chamber.
In another aspect, the blowers are operable to blow the air at a high velocity through at least two of the coil panels, and across the cooling coils into the enclosed chamber.
In another aspect, the blowers are operable to blow the air at a high velocity of about 1,000 feet per minute through at least two of the coil panels, and across the cooling coils into the enclosed chamber. However, it is significant to note that the CFM does not have to be specific other than the industry standard can be exceeded due to the minimized impact of carry over.
In another aspect, the assembly further comprises a duct or a plenum, the duct or the plenum being joined with the top panel and in fluid communication with the enclosed chamber through the outlet opening, the duct operable to carry the cooled air being sucked by the fan.
In another aspect, the assembly further comprises a bracket that is configured to fasten the fan to the panel that forms the outlet opening.
In another aspect, the drain pan forms a drain hole.
In another aspect, the cooling coils from a fluid inlet operable to enable ingress of the cooling fluid.
In another aspect, the cooling fluid comprises chilled water.
In another aspect, the fan comprises a processor operable to regulate power and speed of the fan.
One objective of the present invention is to provide a miniaturized air handler.
Another objective is to enable increased air flow across the cooling coils (such as 1,000/ft/minute rather than industry standard of 500/ft/minute) without having condensate clog up the air handler components. The air handler assembly allows for velocities in excess of the industry standards due to any carry over that may occur will be limited to the drain.
Yet another objective is to prevent condensate from dripping into air handler and clogging components therein.
Another objective is to retrofit the air handler assembly into an HVAC, or manufacture the air handler with an HVAC system.
Another objective is to increase the BTU's over prior art HVAC systems.
An exemplary objective is to provide a 40-ton capacity air handler. However, it is significant to note that the capacity of the air handler is not necessarily defined, as the capacity is determined by the actual selection of the cooling coils and how many cooling coils are used. Also, the capacity is determined by the CFM of the Fan, evaporator coil size and capacity, Temperature and flow of the Cooling Medium such as Chilled Water.
Additional objectives are to provide an inexpensive to manufacture HVAC system.
Other systems, devices, methods, features, and advantages will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims and drawings.
The invention will now be described, by way of example, with reference to the accompanying drawings, in which:
Like reference numerals refer to like parts throughout the various views of the drawings.
The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms “upper,” “lower,” “left,” “rear,” “right,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in
A miniaturized air handler assembly 100 is referenced in
Additionally, the assembly 100 rests within a perimeter flange of a drain pan 108, such that condensate falling from the cooling coils 302a-f is restricted from flooding components of the air handler. Such a structural configuration, enables a greater velocity of inbound air to flow over the cooling coils 302a-f; thereby increasing BTU's and overall efficiency of the assembly 100. In another novel structural design, the assembly 100 is operable with an HVAC system; either as part of a new A/C unit, or retrofitted to an existing A/C unit.
In one exemplary use, the assembly 100 has a unique configuration of coil panels 102a, 102c that cools incoming air. The coil panels 102a, 102c comprise multiple cooling coils 302a-f, i.e., evaporator cooling coils. The cooling coils 302a-f are sized and dimensioned to carry a cooling fluid, such as chilled water, that cools incoming air. The coil panels and multiple solid panels 102b, 102d, 102e, 102f may join at the edges to form an enclosed chamber 204 where cooled air accumulates before being sucked in to a duct.
In any case, the cooling coils 302a-f are arranged in a continuous, side-by-side relationship with each other while carrying a cooling fluid. When the edges coil panel are joined with other coil panels, or solid panels, the square or rectangular-shaped enclosed chamber 204 is formed. Air is sucked through the coil panels to accumulate into the enclosed chamber, where a fan sucks the cooled air through exterior ducts. Additionally, the coil panels rest atop a drain pan 108, such that all the cooling coils 302a-f are within the perimeter of the drain pan 108, and any falling condensate from blowing air falls into the drain pan 108.
In one possible embodiment, the cooling coils are normally referred to as “Cooling Coils”. In the case of Chilled Water, they are referred to as “Chilled Water Coils” in the case of a DX (Direct Expansion) they are referred to as Cooling coils. And in the case of heating, they can just be referred to as heating coils. or heating elements if electricity is used to heat.
As
In one possible embodiment, the solid panels include two side solid panels 102b, 102d, a top solid panel 102e, and a bottom solid panel 102f join to form the cubicle or rectangular shape of the enclosed chamber. In alternative embodiments, multiple corner reinforcement panels (not shown) may also be used to help seal the enclosed chamber. In any case, the enclosed chamber 204 is generally sealed and weatherproof. Formed from the panels, the enclosed chamber 204 defines a central region 106, which is generally concentric from the inner surfaces of the panels 102a-f. The central region 106 is significant in that cooled air accumulates there before being sucked out into a duct 112a, 112b or plenum. In one embodiment, multiple wheels 122a, 122n at the drain pan or bottom panel enable mobility of assembly 100. Four wheels may be used in one embodiment.
Looking now at
The top solid panel 102e defines an outlet opening 200 (
In alternative embodiments, some of the solid panels may include blank off panels. Depending on capacity and arrangement of the coiling tubes, the blank off panels serve to enclose the enclosed chamber, i.e., coil panel, when all sides are not needed to be an evaporator. The blank off panels can also be used to service the inside portion of cooling coils 302a-f and the drain pan 108. The top panel 102e encloses the enclosed chamber but has an outlet opening 200 to allow the air to flow into the fan 202.
Uniquely, the entire assemblage of panels and cooling coils 302a-f, discussed below, reside on a drain pan 108. The drain pan 108 comprises a surface 304 having a perimeter flange 114. The surface 304 may be slightly sloped to enable condensate drippings to flow out of a drain hole 210 in the side of the drain pan 108. The drain hole 210 may also from at the bottom, or piped to the side of drain pan 108. The surface 304 of the drain pan 108 supporting the panels 102a-f. The panels 102a-f are substantially disposed inside the perimeter flange 114 of the drain pan 108, such that any condensate that drips from the cooling coils falls onto the surface 304 of the drain pan 108, rather than into the components of the assembly 100.
As shown in
In one non-limiting embodiment, the cooling coils 302a-f are evaporator cooling coils. In one embodiment, the coil panels 102a, 102c are disposed at opposite ends, such that incoming air flows over the cooling coils 302a-f from multiple directions. This enhances the cooling effect, allowing for a miniaturized version of air handler. The cooling coils may have a tubular configuration. Any number of cooling coils may also be used on corresponding coil panels 102a, 102c. And any number of coil panels may be used; including two, three, or four that form a cube of coil panels. As the number of coil panels are increased, the BTU's are exponentially increased.
The cooling coils 302a-f form a fluid inlet that is sized and dimension to enable ingress of the cooling fluid from manifold inlet 116a that provides the cooling fluid. In another embodiment, the cooling coils 302a-f have a tubular structure, which may include a circular cross section, or other shapes. As is known in the art, the cooling fluid may pass through a chiller-style system prior to flowing into the assembly 100. The cooling coils 302a-f can be arranged vertically, as illustrated in
For example,
The cooling coils 302a-f are arranged in a back-and-forth continuous configuration for carrying the cooling fluid. In any case, the cooling coils 302a-f are in fluid communication, and have a fluid inlet to receive fluid, and a fluid outlet to discharge fluid. Additionally, at least one screen 124a, 124b may be used to overlay the coil panels 102a, 102c. The screen 124a-b may be an aluminum sheet having apertures or slots to enable ingress of air through the coil panels 102a, 102c.
Significantly, the apertures in the screen enable ingress of air 212a, 212b through cooling coils 302a-f, at opposing sides of the enclosed chamber 204. In one possible embodiment, the apertures are multiple small openings that form a screen. In yet another embodiment, the apertures can be multiple spaced-apart small holes that from across substantially the entire apertured panel. In any case, the capacity to ingress air for passing over the cooling coils 302a-f is enabled. In alternative embodiments, a filter 126 may be integrated into the screen 124a-b.
In some embodiments, the assembly 100 includes a cooling fluid manifold 400 that is configured to regulate the ingress and egress of the cooling fluid through the cooling coils 302a-f. In one non-limiting embodiment, the cooling fluid manifold 400 has have a manifold inlet 116a and a manifold outlet 116b that are in fluid communication with the fluid inlet and the fluid outlet of the cooling coils 302a-f. An inlet fluid tube 118a and an outlet fluid tube 118b can feed the manifold inlet 116a and manifold outlet 116b, respectively. Furthermore, various valves, pressure regulators, and displays known in the art of air handlers may also be used for operation of the cooling fluid manifold 400. The cooling fluid manifold 400 also has multiple circuits to carry fluid to the cooling coils.
For example,
In some embodiments, at least one outlet valve 120a, 120b can help release excess fluid inside the enclosed chamber or drain pan. In alternative embodiments, a manifold of pipes, valves, and other plumbing fixtures may also be used to carry fluid into and out of the cooling coils 302a-f. It is significant to note that different styles of manifolds may be used to feed the cooling coils 302a-f. For example,
Looking again at
In one embodiment, the cooling coils 302a-f and the coil panels 102a, 102c are arranged in a parallel relationship. This may include six vertical cooling coils 302a-f affixed to the inner surface of the coil panels. By affixing to the inner side 300a of the coil panels, the high velocity air flows over the cooling coils 302a-f before entering the enclosed chamber 204. In this manner, air passing through the coil panels accumulate in the central region 106 of the enclosed chamber 204.
In some embodiments, the cooling coils 302a-f are arranged vertically in relation to the coil panels, extending between the top and bottom panels 102e, 102f. Thus, the cooling coils 302a-f extend between the top solid panel 102e and the outlet opening 200, and the solid bottom panel 102f. In another embodiment, the cooling coils 302a-f are arranged horizontally in relation to the coil panels. The horizontal disposition of cooling coils 302a-f traverses the coil panels. In the horizontal configuration there would not be cooling coils 302a-f on the bottom or top panels. In yet another embodiment, the cooling coils 302a-f may extend at a diagonal across the coil panels. In any case, the air passing through cooling coils 302a-f accumulates in the central region 106 of enclosed chamber 204. The illustrations show a cooling coil. However, a typical coil would have multiples of rows of coils attached to fins for increasing the surface area of the heat absorption surface.
This design of cooling coils 302a-f is to create enclosed chamber 204 that is enclosed using any number of cooling coils 302a-f that are straight or curved. The enclosed chamber is formed using a combination of: solid panels, coil panels, the cooling coils 302a-f, drain pan 108, and blank off plates. This forms an enclosed chamber 204 into which the air is drawn into from opposing directions outside the panels 102a-f. This creates an evaporator environment, formed from a combination of panels and cooling coils 302a-f where the air flowing through the cooling coils 302a-f are combined into one air stream into the central region, and subsequently discharged from the enclosed chamber 204 through the fan 202.
Looking again at
In one embodiment, the fan is operable to blow the air at a high velocity through the at least two of the coil panels 102a, 102c, and across the cooling coils 302a-f into the enclosed chamber 204. The fan enables the air to cool and to accumulate in the central region 106 of the enclosed chamber 204. For example, illustrated is two sets of coil panels with opposing airflows blow past the cooling coils 302a-f towards each other into the center of the enclosed chamber 204. This high velocity airflow causes condensate to drip, or fall, off the surface of the cooling coils 302a-f, which in prior art units, flooded the air handler.
Since, the assembly 100 rests within the perimeter flange 114 of the drain pan 108, the condensate falls directly into the drain pan 108 before reaching the components of the assembly 100. This serves to minimize flooding and damage to the air handler. In this manner, more BTU's can be generated by the assembly 100. It is significant to note that because the cooling coils 302a-f and panels 102a-f are disposed within the perimeter flange 114 of the drain pan 108, the velocity can reach 1,000 ft/min. Thus, the condensate that inherently forms on the cooling coils 302a-f falls into the drain pan 108; and thereby does not travel into the subsequent components of the air handler. In one possible embodiment, a bracket 206 is configured to fasten the fan 202 to the top panel 102e, or the panel that forms the outlet opening 200.
The assembly 100 is unique in that the intake of air from opposing coil panels enable the miniaturization of the air handler. The assembly 100 is also unique in that the condensate never reaches the fan 202 or central region 106 of the air handler, because the high velocity airflow causes condensate to drip, or fall, off the surface of the cooling coils 302a-f, and into the drain pan 108. It is known in the art that in prior art units, such condensate flooded the air handler.
The assembly 100 reduces the space needed for an air conditioning unit in comparison to an air conditioner unit of similar capacity. In this manner, the assembly 100 creates a more compact air conditioning unit that takes up less space, and is easier to install and replace. Rather than air flow through a single panel of cooling coils 302a-f, i.e., evaporator cooling coils in one direction, the assembly 100 uses multiple panels with cooling coils 302a-f, where the air flows from opposing coil panels from opposing directions.
As an example of how the design of the assembly 100 (miniaturized Air Handler Unit) increases capacity and can decrease the size. A standard 6 row chilled water coil has a measurement of 24″ wide and 40″ height with a total capacity of 84,000 BTU's with a standard face velocity of around 500ft/min.
With this novel invention the BTU capacity can be doubled by using two apposed flow coils (coil panels), tripled by adding three apposed flow coils, and quadrupled by having four apposed flow coils without increasing the size of the unit. So, within an assembly 100 that is just 34″×34″ the total capacity can be increased from 84,000 BTU's to 336,000 BTU's. This is an incredible increase in capacity within a very small space.
Beyond the ability to maximize the space by the design of this Novel AHU, the assembly 100 can exceed the industry standard face velocity of the coil, which further increases the BTU capacity of the unit without increasing the size of the unit. This is possible because the negative consequence that comes from exceeding the standard face velocity of about 500 ft/min which causes moisture carryover is mitigated.
As a further example, the coils that are in the assembly 100 shown in the illustration have a BTU capacity of 241,000 BTU's at a face velocity of 700 ft/min. Thus, with two opposed coils, the capacity would be 482,000 BTU's; and with three apposed coils the capacity is 723,000 BTU's; and four coils creates a cube having a capacity of 964,000 BTU's in a space approximately 3′×3′ and 45″ tall. This creates 80 tons of coiling capacity within a very small space. This is an example of how the design is Novel and truly minimizes the size of an Air Handling Unit.
In operation, the fan 202 draws the air into the enclosed chamber 204 and through the cooling coils 302a-f into the enclosed chamber 204 created by the closed in cooling coils 302a-f. The air is cooled as it passes through the cooling coils into the central region 106. The fan 202 removes the combined air of the cooling coils 302a-f from the chamber 204 discharging it from the fan 202 into the duct 112a, 112b or plenum to condition the area it is to serve.
Advantageously, the assembly 100 can be used in multiple applications. In a first embodiment, the assembly 100 can be installed as part of a new AC unit where the needed space for an air handler is decreased. In a second embodiment, the assembly 100 can be part of an older air handler retrofit to replace old cooling coils and fans. In this instance it can simplify the installation of a new coil and fan 202 unit as it can fit through smaller openings and passageways. In a third embodiment, the assembly 100 can also be used as a standalone temporary air conditioning unit that takes up less space than a conventional temporary air conditioning unit. Additionally, the assembly 100 can be used in Heating, Ventilation or Air conditioning. In another embodiment, a hot fluid is utilized in the cooling coils to heat, rather than to cool. In this heating configuration, the coil panel works in substantially the same manner as described above for cooling.
These and other advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims and appended drawings.
Because many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalence.
This application claims the benefits of U.S. provisional application No. 63,116,497, filed Nov. 20, 2020 and entitled COOLING COIL DESIGN FOR CHILLED WATER AND DX AIR HANDLERS, PACKAGE UNITS AND TEMPORARY AIR UNITS, which provisional application is incorporated by reference herein in its entirety.
