MODULAR HUMIDIFIER SYSTEM

Information

  • Patent Application
  • 20240369245
  • Publication Number
    20240369245
  • Date Filed
    May 02, 2024
    6 months ago
  • Date Published
    November 07, 2024
    15 days ago
Abstract
A modular 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 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.
Description
BACKGROUND

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.


SUMMARY

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.





BRIEF DESCRIPTION OF THE FIGURES

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:



FIG. 1 is a front perspective view of a humidifier system, according to an exemplary embodiment.



FIG. 2 is a back perspective view of the humidifier system of FIG. 1, according to an exemplary embodiment.



FIG. 3 is a perspective view of a base within the humidifier system of FIG. 1, according to an exemplary embodiment.



FIG. 4 is a drain control assembly within the humidifier system of FIG. 1, according to an exemplary embodiment.



FIG. 5 is a perspective view of a wet pack assembly within the humidifier system of FIG. 1, according to an exemplary embodiment.



FIG. 6 is a perspective view of a fan module assembly within the humidifier system of FIG. 1, according to an exemplary embodiment.



FIG. 7 is a perspective view of a bypass assembly within the humidifier system of FIG. 1, according to an exemplary embodiment.



FIG. 8 is a cover assembly within the humidifier system of FIG. 1, according to an exemplary embodiment.



FIG. 9 is an exploded view of the fan module assembly of FIG. 6, according to an exemplary embodiment.



FIG. 10A is a back perspective view of the base of FIG. 3, according to an exemplary embodiment.



FIG. 10B is a rear view of the fan module of FIG. 6, according to an exemplary embodiment.



FIG. 11A is a perspective view of the base of FIG. 3 coupled to a module adapter, according to an exemplary embodiment.



FIG. 11B is a side view of the module adapter of FIG. 11A coupled to a portion of the base, according to an exemplary embodiment.



FIG. 12 is a side perspective view of a bypass module within the humidifier system of FIG. 1, according to an exemplary embodiment.



FIG. 13 is a damper assembly for the bypass module of FIG. 12, according to an exemplary embodiment.



FIG. 14A is a front perspective view of the humidifier system of FIG. 1 coupled to a fan module on a first side, according to an exemplary embodiment.



FIG. 14B is a back perspective view of the humidifier system of FIG. 14A, according to an exemplary embodiment.



FIG. 15 is a perspective view of the humidifier system of FIG. 1 coupled to a fan module on a second side, according to an exemplary embodiment.



FIG. 16 is a perspective view of the humidifier system of FIG. 1 and a cover assembly, according to an exemplary embodiment.



FIG. 17 is a cross-sectional view of the humidifier system of FIG. 16 near a corner, illustrating overlap between a cover handle and the base, according to an exemplary embodiment.



FIG. 18 is a top cross-sectional view of the humidifier system of FIG. 1, illustrating the drainage assembly, according to an exemplary embodiment.



FIG. 19 is a perspective view of the drainage assembly of FIG. 18, according to an exemplary embodiment.



FIG. 20 is a side cross-sectional view of the drainage assembly of FIG. 18 near a valve, according to an exemplary embodiment.



FIG. 21 is a partially exploded view of the humidifier system of FIG. 1 with a fan module, according to an exemplary embodiment.



FIG. 22 is a perspective view of the humidifier system of FIG. 1 with a fan module, according to an exemplary embodiment.



FIG. 23 is a perspective view of fan units for the fan module of FIG. 22, according to an exemplary embodiment.



FIG. 24 is an end view of an outlet of the fan module of FIG. 22, according to an exemplary embodiment.



FIG. 25 is a rear view of the fan module of FIG. 22, according to an exemplary embodiment.





DETAILED DESCRIPTION

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 FIGS. 1-2, a humidifier system 100 is shown, according to an exemplary embodiment. The humidifier system 100 is configured to increase an amount of humidity within a space (e.g., building, room, home, etc.). In various embodiments, the humidifier system 100 may be a standalone system that may be disposed within a particular space to increase humidity therein. In other embodiments, the humidifier system 100 may be coupled to or included within a HVAC system. The humidifier system 100 includes or is coupled to a water source (e.g., water supply to a structure, building, house, etc.). The humidifier system 100 may include a control module, which may have one or more sensors configured to sense the humidity within a space. The control module may also include one or more controllers, which are in communication with the one or more sensors and are configured to control operation of the humidifier system 100 based on one or more signals received from the one or more sensors.


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 FIGS. 1-2, the humidifier system 100 may include the base module 105, which may be coupled to a fan module 110 and a cover assembly 115. The humidifier system 100 may include a drainage assembly 120, which is fluidly coupled to a wet-pack assembly 127 disposed in the base module 105. The humidifier system 100 also includes a power connection 125, which may couple the humidifier system 100 to a power source.


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 FIGS. 3-5, the base module 105 includes a base frame 130, which is structured to contain the wet-pack assembly 127. The frame 130 includes structural members 133, which are structured to enclose sides of the wet-pack assembly 127, and a drainage tray 135, which is fluidly coupled to the drainage assembly 120. The drainage assembly 120 includes a housing 140, which houses a valve assembly 145. The valve assembly 145 controls water flow from the drainage tray 135 to an outlet 150, from which water from the wet-pack assembly 127 may either flow away from the humidifier system 100 or may be recirculated.


As shown in FIG. 5, the wet-pack assembly 127 includes a water panel 165, which is held within a distribution tray and frame assembly 160. Water from the water source may be provided to a portion of the distribution tray and frame assembly 160 near an uppermost part of the water panel 165, where water may then flow through the water panel 165 toward a scale control tray 170, which is disposed at a bottom portion of the distribution tray and frame assembly 160. In various embodiments, water from the scale control tray 170 may be recirculated through the water panel 165 via a feed tube 167 or it may flow through the drainage tray 135 to the drainage assembly 120.



FIG. 6 shows a perspective view of the fan module 110, according to an exemplary embodiment. The fan module 110 includes a fan cover portion 175 (e.g., a finger guard) and a fan mount portion 177, which couples to the fan cover portion 175. The fan mount portion 177 is structured to enclose a fan or blower 180, which circulates air from the base module 105 through the humidifier system 100. The fan module 110 includes a coupling region 185, which may include one or more holes, recesses, grooves, or features structured to facilitate coupling the fan module 110 to the base module 105. As shown in FIG. 6, the fan cover portion 175 and the fan mount portion 177 form an outlet 190 at a first end, into which air from the base module 105 is drawn. The fan cover portion 175 and the fan mount portion 177 also form an outlet 195 at a second end, from which humidified air is forced out through the ends of the fan 180. In particular, a vacuum pressure is created within the fan cover portion 175 (and the fan mount portion 177) that draws in air (e.g., through the water panel 165 first then through the fan 180) and forces it out through the outlets 190. As previously described, the fan module 110 may be selectively coupled to the base module 105 (via the coupling region 185) to accommodate one or more use applications.


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 FIG. 7, the humidifier system 100 may be structured such that the bypass module 200 is coupled to each of the base module 105 and the cover assembly 115. The bypass module 200 may include a frame portion 207, which defines a duct 205. The duct 205 may scavenge airflow for humidification from the warm dry supply side of the base module 105 (e.g., from within an HVAC system coupled to the humidifier system 100) to a cooler return side through an evaporator within the humidifier system 100 (e.g., adjacent to or within the base module 105). As described previously, the humidifier system 100 includes a cover assembly 115, which is structured to couple to the base module 105 and selectively couple to the bypass module 200 (or the fan module 110). As shown in FIG. 8, the cover assembly 115 may include a lip or handle 210, which may be separately coupled or integrally formed within the cover assembly 115. The handle 210 may be structured to facilitate separation and removal of the cover assembly 115 from the base module 105 and the bypass module 200 (or from the fan module 110). In various embodiments, the cover assembly 115 is structured to couple to an open side of the base module 105 opposite a side of the base module 105 that is structured to couple to the fan module 110 and/or the bypass module 200, as shown in FIG. 8. Such a configuration eliminates a need for additional components to connect between the cover assembly 115, the base module 105, and/or any additional modules within the system 100. In various embodiments, the cover assembly 115 includes a thumb latch and snap assembly disposed along an outer edge of the cover assembly 115, where the thumb latch and snap assembly is structured to connect the cover assembly 115 to the base module 105 and the fan module 110 (and/or the bypass module 200).



FIG. 9 shows an exploded view of the fan module 110, according to an exemplary embodiment. As illustrated, the fan cover portion 175 is configured to couple to the fan mount portion 177. The fan mount portion 177 includes an anchor portion 220 and a frame portion 225, where the anchor portion 220 includes one or more grooves, recesses, or apertures 215, which form the coupling region 185 of the fan module 110. The anchor portion 215 is disposed adjacent the frame portion 225, where the frame portion 225 forms a containment structure (e.g., cage) to enclose the fan 180 within the fan module 110.


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 FIG. 10A, the frame 130 of the base module 105 may include a mounting region 241, which includes one or more grooves, recesses, or apertures 243. Similarly, as shown in FIG. 10B, the cover portion 175 of the fan module 110 may include one or more grooves, recesses, or apertures 245, which may be disposed within an end of the cover portion 175 that is adjacent the base module 105 when the fan module 110 is coupled to the base module 105. The apertures 243 are structured to receive one or more fasteners (e.g., hooks, screws, etc.), which may also extend through the one or more apertures 245 disposed within the cover portion 175 to couple the base module 105 to the fan module 110. In various embodiments, the apertures 243 and/or the apertures 245 may be structured to facilitate mounting of the humidifier system 100 (e.g., within an HVAC system, within a home, etc.).


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 FIGS. 11A and 11B, the fan mount portion 177 may include one or more protrusions 250 extending from a region of the anchor portion 220, which are structured to engage with one or more corresponding slots 270 disposed within the frame 130 of the base module 105. As shown, the protrusions 250 and the slots 270 may connect at a joint 255 to couple the fan mount portion 177 to the frame 130. As illustrated in FIG. 11B, the protrusions 250 may include a T-shaped protrusion or ridge 275, which is structured to be received within a correspondingly T-shaped slot 270 of the frame 130. The one or more protrusions may also include additional ridges 280, which may engage with one or more corresponding recesses disposed within the frame 130 to facilitate a secure connection between the base module 105 and the fan module 110. In various embodiments, the frame 130 may also include one or more snap retention features 260 (e.g., locking push tabs), which are configured to engage with one or more protruding features 265 of the fan mount portion 177 to form a snap fit connection therebetween. Accordingly, the base module 105 may be disconnected from the fan module 110 (or the bypass module 200) by pressing on the snap retention features 260. In some embodiments, the T-shaped slot 270 is disposed along a side of the frame 130 that is perpendicular to a side of the frame 130 within which the snap retention features 260 are disposed. Similarly, the T-shaped protrusion 275 may be disposed along a side of the fan module 110 that is perpendicular to a side of the fan module 110 that includes the protruding features 265. As shown in FIG. 11A, the frame 130 may include slots 270 and snap retention features 260 disposed on opposing sides of the frame 130 to enable selective coupling of the fan module 110 to either side of the frame 130 (and thus either side of the base module 105).


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 FIG. 12, the frame portion 207 of the bypass module 200 includes a duct 205. In various embodiments, the duct 205 may be structured to receive an adapter assembly 300. In some embodiments, the adapter assembly 300 includes a reducer 305, which may reduce a diameter of the airflow pathway through the duct 205. For example, the duct 205 may have an 8-inch diameter without the adapter assembly 300, which may reduce to a 6 in diameter when the adapter assembly 300 is connected within the duct 205. In some embodiments, the bypass module 200 may be coupled to the adapter assembly 300 based on a humidification need. For example, the adapter assembly 300 may not be coupled to the bypass module 200 if a higher airflow and higher evaporation rate is required by the humidifier system 100. Conversely, if a lower airflow and lower evaporation rate is required by the humidifier system 100, the adapter 300 may be coupled to the bypass module 200. In some embodiments, the adapter assembly 300 includes one or more dampers 310, which may be configured to selectively allow or block airflow through the humidifier system 100. In various embodiments, the one or more dampers 310 may be removable or fixed within the bypass module 200. In various embodiments, one or more dampers 310 may include one or more indicators on a damper position dial to facilitate positioning of the one or more dampers 310 according to known airflows and/or water evaporation rates.


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 FIGS. 14A-B, the fan module 110 may be structured to couple to a first side 315 of the base module 105 such that air flows toward the first side 315 of the base module 105. In other embodiments, such as shown in FIG. 15, the fan module 110 may couple to a second side 320 of the base module 105 such that air flows toward the second side 320 of the base module 105. Accordingly, the humidifier system 100 may be adapted based on a particular application, unlike standard systems which either have axial fans with dual symmetric exhaust ports or fixed exhaust ports-neither of which can be reconfigured For example, in some embodiments, the humidifier system 100 may be used in horizontal flow applications such as in attic installations of HVAC equipment. In such applications, the modularity of the fan module 110 within the humidifier system 100 (i.e., that the fan module 110 can be attached to the base module 105 in various configurations) may offer distinct performance advantages over non-modular systems as the humidifier system 100 may be reconfigured based on a direction of airflow (e.g., horizontal). Reconfiguring the humidifier system 100 based on airflow direction may enable optimization of inlet and outlet placement to avoid recirculating humidified air.


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 FIG. 16, the cover assembly 115 is structured to engage internally with the base module 105 along a first seam 325 and along a second seam 327. The cover assembly 115 may also engage with the fan module 110 (or with the bypass module 200) along a second seam 326. At each of the seams 325 and 327, an edge of the cover assembly 115 may overlap with an edge of the frame 130 within the base module 110. For example, as shown in FIG. 17, the cover assembly 115 may include a lip 335, which overlaps with an edge of the frame 130. The overlapping arrangement prevents water leakage. In various embodiments, the cover assembly 115 may include a handle 330, which extends outward from the cover assembly 115 and facilitates separation of the cover assembly 115 from the base module 105 and the fan module 110 (or the bypass module 200).


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 FIG. 18, a bottom surface 337 of the cover assembly 115 may be sloped such that collected water within the cover assembly 115 may flow toward the drainage tray 135. Similarly, a bottom surface 340 of the frame 130 may be sloped such that water collected within the drainage tray 135 flows into the drainage assembly 120 to be removed from the humidifier system 100.


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 FIGS. 19 and 20. As illustrated, the drainage assembly 120 includes a housing 140, which nests within an opening disposed in the drainage tray 135 of the frame 130. The housing 140 contains a valve assembly 145, which controls flow of water flowing to the humidifier system 100. In some embodiments, the humidifier system includes a drain spud molded into the housing 140 to control waste water flowing from the drainage tray 135 away from the humidifier system 100. In various embodiments, the valve assembly 145 may include one or more check valves, solenoid valves, or any other valve suitable for controlling a water flow. As shown, when the drainage assembly 120 is coupled to the drainage tray 135, a portion 347 of the housing 140 overlaps with a portion 360 of the drainage tray 135 to prevent water leakage. In various embodiments, the drainage assembly 120 may be structured such that the housing 140 includes a ridge or groove disposed along an upper portion, where a bead or ridge disposed within a bottom portion of the drainage tray 135 is receivable within the groove of the housing 140.


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 FIG. 21. In other embodiments, the humidifier system 100 may instead be assembled such that the fan module 110 couples to a second side 375 of the base module 105 and the cover assembly 115. In yet other embodiments, the humidifier system 100 may include one or more fan modules 110 that may be structured to couple to one or more sides of the base module 105. Furthermore, as described above, the fan module 110 may be selectively couplable to each of the base module 105 and the cover assembly 115 via one or more releasable connections (e.g., snap fit connectors). Accordingly, the humidifier system 100 may be readily customizable based on a particular use application. For example, the fan module 110 may be coupled to the base module 105 and the cover assembly 115 and later removed to allow coupling of the bypass assembly 200 to the base module 105 and the cover assembly 115. Such a configuration of the humidifier system 100 enables a user to readily upgrade one or more components of the humidifier system 100 (e.g., to include components with new or enhanced features) at a lower overall cost than replacing the entirety of the humidifier system 100.


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 (FIG. 22). In various embodiments, the fan 180 may include a single fan. In other embodiments, the fan 180 may include a dual fan assembly balanced about a central motor, as shown in FIG. 23. In some embodiments, the fan 180 may be a dual assembly having cages 380 to facilitate air cross flow. In other embodiments, the fan 180 may be a dual assembly with a scroll housing 385 to create four air inlets.


As shown in FIG. 23, the cages 380 and the housings 385 (which each contain a fan unit) straddle motors 383 and 387, respectively, where the motor 383 and 387 drive movement of air (e.g., via fan blades, impellers, etc.). Structuring the fan 180 such as shown in FIG. 23 enables reduction in size and footprint of the fan module 110 as such a configuration does not require long blades or numerous supports. Instead, such as shown in FIG. 24, the fan 180 may be aligned within the fan module 110 such a long axis of the fan 180 is substantially parallel with a long axis of the both the fan mount portion 177 and the fan cover portion 175. In various embodiments, the fan mount portion 177 and the fan cover portion 175 are structured to form an enclosure around the fan 180 to secure the fan 180 within the fan module 110. Accordingly, when the humidifier system 100 is operating, air (e.g., from the base module 105) may flow into ends 390 and 390 of the fan 180, which are furthest from the central motor (e.g., motor 387 or 383) and into the ends 393 and 395, which are closest to the central motor (e.g., motor 387 or 383). Air drawn into the fan 180 may then flow through the outlet 190 into a surrounding area.


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 FIG. 25, disposed within the fan module 110. The speed selection switch 400 may be communicably coupled to the fan 180 (and the control module within the humidifier system 100) and may be configured to control an operation speed of the fan 180. In various embodiments, the switch 400 may be disposed within the fan mount portion 177. In other embodiments, the switch 400 may be disposed on an external portion of the fan module 110 (e.g., on an outer region of the fan cover portion 175). In yet other embodiments, the switch 400 may operate in response to a remote signal sent by a user device or other control device. In various embodiments, the switch 400 may cause the fan 180 to operate at a first setting corresponding to a higher speed or a second setting corresponding to a lower speed.


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 FIGS. 1-25, various modifications and inclusions to those embodiments are contemplated and considered within the scope of the present disclosure.


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.

Claims
  • 1. A modular humidifier system comprising: a base module comprising a frame and a wet-pack assembly, the wet-pack assembly being enclosed in the frame;a fan module structured to draw air through the base module; anda cover assembly structured to couple to each of the fan module and the base module;wherein the frame comprises a first side and a second side, and wherein the fan module is structured to selectively couple to either the first side or the second side.
  • 2. The humidifier system of claim 1, wherein 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.
  • 3. The humidifier system of claim 2, wherein the cover assembly comprises a thumb latch and snap assembly, the thumb latch and snap assembly configured to connect the base module and the fan module to the cover assembly.
  • 4. The humidifier system of claim 1, wherein the fan module comprises a mount portion and a cover portion.
  • 5. The humidifier system of claim 1, wherein the fan module further includes a fan, and wherein 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.
  • 6. The humidifier system of claim 5, wherein the fan comprises: a body having a first cylindrical portion and a second cylindrical portion;a motor portion disposed between the first cylindrical portion and the second cylindrical portion;wherein 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;wherein each of the first and second cylindrical portions comprises 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; andwherein each of the first and second cylindrical portions comprises an outlet, the outlet 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.
  • 7. The humidifier system of claim 1, further comprising a drainage assembly fluidly coupled to the base module, wherein water from the wet-pack assembly flows into the drainage assembly.
  • 8. The humidifier system of claim 7, wherein the cover assembly comprises a sloped bottom surface, the bottom surface coupled to the base module such that water collected within the cover assembly flows from the bottom surface to the drainage assembly.
  • 9. The humidifier system of claim 7, wherein the drainage assembly comprises a housing and a valve assembly disposed within the housing, the housing being connected to the base module.
  • 10. The humidifier system of claim 9, wherein the valve assembly comprises at least one of a check valve or a solenoid valve.
  • 11. The humidifier system of claim 1, wherein 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.
  • 12. The humidifier system of claim 1, wherein: the fan module comprises: a T-shaped protrusion disposed along a first side of the fan module; andat least one protruding feature disposed along a second side of the fan module perpendicular to the first side of the fan module; andthe frame comprises: a T-shaped slot disposed along a first side of the frame, the T-shaped slot structured to receive the T-shaped protrusion; andone or more snap fit retention features disposed along a second side of the frame perpendicular to the first side of the frame, the one or more snap retention features structured to engage with the at least one protruding feature.
  • 13. The humidifier system of claim 1, wherein the fan module is structured to couple to the first side or the second side based on a use application of the humidifier system.
  • 14. The humidifier system of claim 6, wherein the fan module further comprises a speed control switch communicably coupled to the fan, wherein the speed control switch is configured to control a speed of operation of the fan.
  • 15. The humidifier system of claim 14, further comprising at least one sensor in communication with the speed control switch, wherein 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.
  • 16. The humidifier system of claim 14, wherein 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.
  • 17. A modular humidifier system comprising: a base module comprising a frame and a wet-pack assembly, the wet-pack assembly being enclosed in the frame;a bypass module comprising a duct structured to draw air through the base module; anda cover assembly structured to couple to each of the bypass module and the base module;wherein the frame comprises a first side and a second side, and wherein the bypass module is structured to selectively couple to either the first side or the second side.
  • 18. The humidifier system of claim 17, wherein the bypass module further comprises an adapter configured to couple to the duct.
  • 19. The humidifier system of claim 17, wherein the adapter reduces a diameter of an air pathway through the duct to reduce airflow through the duct.
  • 20. The humidifier system of claim 17, wherein the adapter comprises at least one damper.
  • 21. The humidifier system of claim 13, wherein the bypass module is structured to selectively couple to either the first side or the second side via a snap fit connector.
CROSS-REFERENCE TO RELATED APPLICATIONS

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.

Provisional Applications (1)
Number Date Country
63463796 May 2023 US