Patent Application
20240369245
The present disclosure relates generally to humidifying systems for increasing humidity of ambient air. More specifically, the present disclosure relates to a modular humidifier system, which may be customizable to achieve various styles and configurations to meet installation requirements in a home or other structure.
One aspect of the present disclosure relates to a modular humidifier system. The humidifier system includes a base module having a frame and a wet-pack assembly, the wet-pack assembly being enclosed in the frame. The humidifier system further includes a fan module structured to draw air through the base module and a cover assembly structured to couple to each of the fan module and the base module. The frame includes a first side and a second side, where the fan module is structured to selectively couple to either the first side or the second side.
In various embodiments, the cover assembly is structured to couple to the other of the first side or the second side such that the cover assembly connects directly to the base module and the fan module. In some embodiments, the cover assembly includes a thumb latch and snap assembly, where the thumb latch and snap assembly is configured to connect the base module and the fan module to the cover assembly. In other embodiments, the fan module includes a mount portion and a cover portion. In various embodiments, the fan module further includes a fan, where the mount portion and the cover portion form an enclosure, the fan being contained within the enclosure and configured to pull air through the wet-pack assembly. In some embodiments, the fan includes a body having a first cylindrical portion and a second cylindrical portion, and a motor portion disposed between the first cylindrical portion and the second cylindrical portion. Each of the first and second cylindrical portions include a first end and a second end opposite the first end, the first end being disposed adjacent the motor portion and the second end being spaced from the motor portion. Each of the first and second cylindrical portions includes a first inlet and a second inlet, the first inlet being disposed at the first end and the second inlet being disposed at the second end. Each of the first and second cylindrical portions includes an outlet, the outlet being structured such that air flowing through the fan flows through the outlet in a direction perpendicular to a direction of airflow through each of the first and second inlets.
In various embodiments, the humidifier system includes a drainage assembly fluidly coupled to the base module, where water from the wet-pack assembly flows into the drainage assembly. In some embodiments, the cover assembly includes a sloped bottom surface, the bottom surface being coupled to the base module such that water collected within the cover assembly flows from the bottom surface to the drainage assembly. In other embodiments, the drainage assembly includes a housing and a valve assembly disposed within the housing, the housing being connected to the base module. In some embodiments, the valve assembly includes at least one of a check valve or a solenoid valve. In other embodiments, opposing edges of the cover assembly are structured symmetrically such that the cover assembly is structured to connect to each of the fan module and the base module such that the opposing edges overlap with an edge of the base module and enable mounting of the humidifier system within a structure. In various embodiments, the fan module includes a T-shaped protrusion disposed along a first side of the fan module, at least one protruding feature disposed along a second side of the fan module perpendicular to the first side of the fan module. The frame includes a T-shaped slot disposed along a first side of the frame, the T-shaped slot structured to receive the T-shaped protrusion, and one or more snap fit retention features disposed along a second side of the frame perpendicular to the first side of the frame, where the one or more snap retention features are structured to engage with the at least one protruding feature.
In various embodiments, the fan module is structured to couple to the first side or the second side based on a use application of the humidifier system. In some embodiments, the fan module further includes a speed control switch communicably coupled to the fan, where the speed control switch is configured to control a speed of operation of the fan. In other embodiments, the humidifier system includes at least one sensor in communication with the speed control switch, where the speed control switch is configured to control the speed of the fan based on at least one metric relating to air within or surrounding the humidifier system, the at least one metric being sensed by the at least one sensor. In some embodiments, the at least one metric includes at least one of a humidity level, a humidification demand, an air temperature, an air pressure, or a blower speed of an HVAC system coupled to the humidifier system.
Another aspect of the present disclosure relates to a modular humidifier system. The humidifier system includes a base module having a frame and a wet-pack assembly, the wet-pack assembly being enclosed in the frame. The humidifier system also includes a bypass module having a duct structured to draw air through the base module a cover assembly structured to couple to each of the bypass module and the base module. The frame includes a first side and a second side, where the bypass module is structured to selectively couple to either the first side or the second side.
In various embodiments, the bypass module further includes an adapter configured to couple to the duct. In some embodiments, the adapter reduces a diameter of an air pathway through the duct to reduce airflow through the duct. In other embodiments, the adapter includes at least one damper. In yet other embodiments, the bypass module is structured to selectively couple to either the first side or the second side via a snap fit connector.
The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements, in which:
Before turning to the figures, which illustrate certain exemplary embodiments in detail, it should be understood that the present disclosure is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology used herein is for the purpose of description only and should not be regarded as limiting.
Generally, the present disclosure relates to a humidifier system having a base assembly that may be selectively coupled to at least one of a bypass module or a fan module to facilitate integration within a heating, ventilation, and air condition (HVAC) system to accommodate a particular humidification need within a structure. The humidifier system may also be structured to allow for future upgrades without needing replacement of the system entirely (e.g., including one or more smart modules, upgraded fan modules, etc.). The humidifier system may be configured such that the base module includes coupling regions on multiple sides such that the bypass module and/or fan module may selectively couple to the base in multiple different configurations. In various embodiments, the bypass module may be structured to include a round duct. In other embodiments, the bypass module may adapt to a round duct via one or more adapters. For example, in some embodiments, the initial shape of the bypass module may be oval (or another shape) to allow for an overall thinner profile of the bypass module and of the humidifier system. In some embodiments, the duct may scavenge airflow for humidification from a warm dry supply side of the HVAC system to a cooler return side through an evaporator within the humidifier system. In various embodiments, the fan module may include one or more fans for circulating humidified air into or through the HVAC system. The bypass module and/or fan module may be structured such that may couple to one or more sides of the base so the humidifier system may be adapted to a particular use or structure.
Referring to
In various embodiments, the humidifier system 100 may include a base module 105, which is structured to couple to at least one functional unit and a cover assembly. In various embodiments, the at least one functional unit may include at least one of a fan module, a bypass module, or a detection and control module (e.g., “smart module”). As shown in
The wet-pack assembly 127, which is disposed within the base module 105, is fluidly coupled to a water source. The water source is in communication with the control module and, accordingly, water from the water source may flow to the wet-pack assembly 127 responsive to control signals from the control module. The fan module 110 is operably coupled to each of the control module and the wet-pack assembly 127. The circulation module 110 may include one or more fans, blowers, or other mechanisms configured to distribute humidified air from the wet-pack assembly 127 within the humidifier system 100. During operation, the humidifier system 100, responsive to a control signal from the control module, circulates water from the water source to the wet-pack assembly 127. The fan module 110 circulates air through the wet-pack assembly 127 where its humidity is increased due to evaporation of the water from the wet-pack assembly 127 and the humidified air moved into the surrounding space.
As shown in
As shown in
In various embodiments, the fan cover portion 175 is structured as a guard (e.g. finger guard) to prevent unintended or unintentional engagement with a user (e.g., a user's finger entering or contacting the fan 180). In some embodiments, the fan cover portion 175 or the fan mount portion 177 includes one or more vents or grills 196 disposed within the outlet 195, which are structured to enable air flow therethrough.
In other embodiments, the base module 105 may be structured to couple to a bypass module 200 (in addition to or instead of the fan module 110). As shown in
As shown, the fan 180 may be a hybrid or centrifugal fan, having a generally cylindrical body 230. The body 230 includes a central motor portion 237 disposed between two cylindrical portions. Each of the cylindrical portions includes a central bore into which air is drawn through inlets 240. As shown, the body 230 is structured such that each cylindrical portion includes a first end and a second end, where the first end is disposed adjacent the motor portion 237 and the second end is disposed opposite the first end spaced from the central motor 237. As shown, the body 230 is structured to include an inlet 240 disposed at each of the first end and the second end of the cylindrical portion (i.e., adjacent the central motor portion 237 and distal to the motor portion 237) such that the body 230 includes four inlets 240). Accordingly, when the fan 180 is running, air may be pulled in through each of the inlets 240 and forced out of the outlets 235.
As shown, the frame portion 225 may include a bridge piece 221 (e.g., a finger guard, bracket), which is structured to surround at least a portion of the motor portion 237. To retain the fan 180, the bridge piece 221 may clamp to one or more retention features 222 disposed within the fan cover portion 175. Accordingly, the frame portion 225 retains the fan 180 between the fan cover portion 175 and the fan mount portion 177 via a connection (e.g., snap fit, friction fit, interference fit, etc.) between the bridge piece 221 and the one or more retention features 222, in addition to the connection between the anchor portion 215 and the coupling region 185. In this manner, the fan 180 itself is not coupled to either the fan cover portion 175 or the fan mount portion 177. Instead, the fan 180 is clamped between the fan cover portion 175 and the fan mount portion 177 (i.e., such that the fan 180 is sandwiched therebetween). The bridge piece 221 is structured to facilitate user safety and longevity of the fan 180 by preventing foreign objects from entering or engaging with the fan 180. In various embodiments, the bridge piece 221 is structured to both cover and isolate electrical components within the fan 180. In some embodiments, the bridge piece 221, together with the fan cover portion 175 (and/or the fan mount portion 177), forms a smooth and expanding outlet path (i.e., via the walls of the portions 175 and 177 and angular shape thereof) to facilitate airflow through the humidifier system 100 and enhance performance.
As shown, the fan 180 may include two outlets 235, where a first outlet 235 is disposed along a first of the cylindrical portions and a second outlet 235 is disposed along a second of the cylindrical portions. In various embodiments, each of the outlets 235 is aligned with a long axis of each of the cylindrical portions such that air flows in a direction perpendicular to air flowing into the fan 180 through each of the inlets 240. For example, when the fan 180 is running within the humidifier system 100, air is pulled into each of the inlets 240 such that air flows around the fan 180 prior to being forced out in a single direction determined by an orientation of the outlet 235. Such an arrangement facilitates mixing of air within the humidifier system 100 and increases efficiency of humidification of ambient air. In various embodiments, the fan 180 (and/or the fan module 110) may be arranged within the humidifier system 100 to facilitate vertical or horizontal air flow through the humidifier system 100.
When the humidifier system 100 is assembled to include the fan module 110, the coupling region 185 formed within the fan mount portion 177 may engage with one or more features of the frame 130 within the base module 105 to couple the fan module 110 to the base module 105. Accordingly, the fan 180 within the fan module 110 may pull air through the wet-pack assembly 127 within the base module 105 to supply humidified air to a surrounding area (e.g., within an HVAC system or within an enclosed area in a structure).
In various embodiments, the fan cover portion 175 may additionally or alternatively form the coupling region 185, which is structured to connect to a portion of the base module 105. As shown in
In various embodiments, the fan mount portion 177 of the fan module 110 may be structured to form an interference fit with the base module 105 to facilitate coupling of the fan module 110 to the base module 105. As shown in
As described above, the bypass module 200 may be additionally or alternatively coupled to the base module 105. For example, in various embodiments, the snap retention features 260 (and/or the slots 270) of the frame 130 may include locking push tabs, which may facilitate engagement and disengagement of the frame 130 from either the fan module 110 or the bypass module 200. Thus, the fan module 110 or the bypass module 200 may be selectively coupled to either side of the frame 130 of the base module 105 via the snap retention features 260. As shown in
As previously discussed, the base module 105 and the fan module 110 (or the base module 105 and the bypass module 200) may be selectively coupled to accommodate a particular use application and/or structure. In various embodiments, the base module 105 and/or the fan module 110 may be structured such that mechanical and electrical components (e.g., wires, electrical placement, etc.) therein are symmetrically arranged therein. Accordingly, the fan module 110 may be flipped 180 degrees relative to the base module 105 for attachment to one or more sides thereof (i.e., via opposite sides of the frame 130). For example, as shown in
Each of the components within the humidifier system 100 are structured to prevent water from flowing outside of designated water pathways. In various embodiments, each of the base module 105, the fan module 110 (or the bypass module 200), and the cover assembly 115 are structured to couple together such that edges of each module overlaps so as to prevent leakage of water from within the humidifier system 100. For example, as shown in
In various embodiments, a bottom portion of the cover assembly 115 may be fluidly coupled to the drainage tray 135 within the base module 105 such that the cover assembly 115 may contribute to collection of entrained water from the wet-pack assembly 127 and facilitate drainage through the drainage tray 135. As shown in
To further prevent water leakage, the drainage assembly 120 may be coupled to the drainage tray 135 via an interference fit such that a portion of the drainage tray 135 overlaps with a portion of the drainage assembly 120, as shown in
As described above, the modular structure of the humidifier system 100 enables adaptability to various different use applications and/or installation requirements. In various embodiments, the humidifier system 100 may be assembled such that the fan module 110 is coupled to a first side 370 of each of the base module 105 and the cover assembly 115, as shown in
In various embodiments, the fan module 110 may be further customized based on a particular use application of the humidifier system 100. As previously described, the fan module 110 includes one or more fans 180, which may be mounted within the fan cover portion 175 and/or the fan mount portion 177 (
As shown in
In various embodiments, the humidifier system 100 may include one or more user interfaces to facilitate operation of the humidifier system 100. In some embodiments, the humidifier system 100 may be configured to operate in response to input from one or more remote controllers (e.g., remote device, user device, etc.). In other embodiments, the humidifier system 100 may include controls designated for each component. For example, in some embodiments, the humidifier system 100 may include a speed selection switch 400, as shown in
In some embodiments, the switch 400 may enable speed control for the purpose of masking sound production of the humidifier system 100 with sound of an HVAC system lower. For example, when operating at a lower speed, the humidifier system 100 may correspond to a low speed HVAC blower and when operating at a higher speed, the humidifier system 100 may correspond to a high speed HVAC blower. In some embodiments, the humidifier system 100 may be configured to operate at a low speed in all situations and the switch 400 may only switch operation to a higher speed in response to a humidity demand and/or in response to a user input (e.g., based on a dwelling type or size, and/or user preference).
In some embodiments, the humidifier system 100 may include one or more sensors communicatively coupled to the switch 400, where the one or more sensors are configured to sense and monitor at least one air metric within or surrounding the humidifier system 100. In some embodiments, the one or more sensors may be configured to sense at least one of an air temperature or a humidity level. In other embodiments, the one or more sensors may be a microphone or air pressure sensor. In various embodiments, the switch 400 may be configured to adjust a speed of a fan (e.g., the fan 180) within the humidifier system 100 based on the air temperature, air pressure, and/or humidity level sensed by the one or more sensors. For example, in some embodiments, the one or more sensors may be configured to monitor air temperature within a duct that is fluidly connected to the base module 105 (e.g., duct 205) and the switch 400 is configured to adjust speed in response.
Notwithstanding the embodiments described above in
As utilized herein with respect to numerical ranges, the terms “approximately,” “about,” “substantially,” and similar terms generally mean+/−10% of the disclosed values, unless specified otherwise. As utilized herein with respect to structural features (e.g., to describe shape, size, orientation, direction, relative position, etc.), the terms “approximately,” “about,” “substantially,” and similar terms are meant to cover minor variations in structure that may result from, for example, the manufacturing or assembly process and are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims.
It should be noted that the term “exemplary” and variations thereof, as used herein to describe various embodiments, are intended to indicate that such embodiments are possible examples, representations, or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative examples).
The term “coupled” and variations thereof, as used herein, means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using a separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of “coupled” provided above. Such coupling may be mechanical, electrical, or fluidic.
References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below”) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.
The hardware and data processing components used to implement the various processes, operations, illustrative logics, logical blocks, modules and circuits described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose single- or multi-chip processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, or, any conventional processor, controller, microcontroller, or state machine. A processor also may be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. In some embodiments, particular processes and methods may be performed by circuitry that is specific to a given function. The memory (e.g., memory, memory unit, storage device) may include one or more devices (e.g., RAM, ROM, Flash memory, hard disk storage) for storing data and/or computer code for completing or facilitating the various processes, layers and modules described in the present disclosure. The memory may be or include volatile memory or non-volatile memory, and may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in the present disclosure. According to an exemplary embodiment, the memory is communicably connected to the processor via a processing circuit and includes computer code for executing (e.g., by the processing circuit or the processor) the one or more processes described herein.
The present disclosure contemplates methods, systems and program products on any machine-readable media for accomplishing various operations. The embodiments of the present disclosure may be implemented using existing computer processors, or by a special purpose computer processor for an appropriate system, incorporated for this or another purpose, or by a hardwired system. Embodiments within the scope of the present disclosure include program products comprising machine-readable media for carrying or having machine-executable instructions or data structures stored thereon. Such machine-readable media can be any available media that can be accessed by a general purpose or special purpose computer or other machine with a processor. By way of example, such machine-readable media can comprise RAM, ROM, EPROM, EEPROM, or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to carry or store desired program code in the form of machine-executable instructions or data structures and which can be accessed by a general purpose or special purpose computer or other machine with a processor. Combinations of the above are also included within the scope of machine-readable media. Machine-executable instructions include, for example, instructions and data, which cause a general purpose computer, special purpose computer, or special purpose processing machines to perform a certain function or group of functions.
Although the figures and description may illustrate a specific order of method steps, the order of such steps may differ from what is depicted and described, unless specified differently above. Also, two or more steps may be performed concurrently or with partial concurrence, unless specified differently above.
It is important to note that any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein. Although only one example of an element from one embodiment that can be incorporated or utilized in another embodiment has been described above, it should be appreciated that other elements of the various embodiments may be incorporated or utilized with any of the other embodiments disclosed herein.
The present application claims the benefit of and priority to U.S. Provisional Patent Application No. 63/463,796, filed May 3, 2023, the entire disclosure of which is hereby incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 63463796 | May 2023 | US |
