Momentum Based Blower Interstitial Seal

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not applicable.

BACKGROUND

Heating, ventilation, and/or air conditioning (HVAC) systems may generally be used in residential and/or commercial structures to provide heating and/or cooling in order to create comfortable conditions inside climate conditioned areas associated with such structures. To provide an airflow of conditioned air into such conditioned areas, most HVAC systems employ a fan to move the conditioned air through the HVAC system and into the climate conditioned areas. Further, to maximize performance of the HVAC system, it is crucial to maximize the performance and/or efficiency of the fan.

SUMMARY OF THE DISCLOSURE

In some embodiments, a blower assembly is disclosed as comprising: a blower housing comprising at least one air inlet; and an impeller comprising a momentum based interstitial seal; wherein the momentum based interstitial seal is configured to orient leakage between the blower housing and the impeller against an incoming airflow entering the at least one air inlet.

In other embodiments, a heating, ventilation, and/or air conditioning (HVAC) system is disclosed as comprising: a component; and a blower assembly configured to generate an airflow through the component, the blower assembly comprising: a blower housing comprising at least one air inlet; and an impeller comprising a momentum based interstitial seal; wherein the momentum based interstitial seal is configured to orient leakage between the blower housing and the impeller against an incoming airflow entering the at least one air inlet.

In yet other embodiments of the disclosure, a method of operating a blower assembly is disclosed as comprising: providing a blower assembly comprising a blower housing and an impeller comprising a momentum based interstitial seal; operating a motor of the blower assembly to rotate the impeller about an axis of rotation to draw an incoming airflow into at least one air inlet of the blower housing in a primary incoming air direction; and orienting leakage between the blower housing and the impeller against the incoming airflow entering the at least one air inlet.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure and the advantages thereof, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description:

FIG. 1 is a schematic diagram of a heating, ventilation, and/or air conditioning (HVAC) system according to an embodiment of the disclosure;

FIG. 2 is a schematic diagram of an air circulation path of the HVAC system of FIG. 1 according to an embodiment of the disclosure;

FIG. 3 is an oblique view of a blower assembly according to an embodiment of the disclosure;

FIG. 4 is a orthogonal side view of the blower assembly of FIG. 3 according to an embodiment of the disclosure;

FIG. 5 is a partial cross-sectional view of the blower assembly of FIGS. 3 and 4 taken along cutting line A-A of FIG. 4 according to an embodiment of the disclosure;

FIG. 6 is a partial cross-sectional view of a blower assembly taken along cutting line A-A of the blower assembly of FIG. 4 according to another embodiment of the disclosure;

FIG. 7 is a detailed partial cross-sectional view of a blower assembly taken along cutting line A-A of the blower assembly of FIG. 4 according to yet another embodiment of the disclosure; and

FIG. 8 is a flowchart of a method of operating a blower assembly according to an embodiment of the disclosure.

DETAILED DESCRIPTION

In some cases, it may be desirable to provide a heating, ventilation, and/or air conditioning (HVAC) system with a blower assembly that minimizes air leakage between the blower housing and the impeller of the blower assembly. For example, in some HVAC systems, it is desirable to apply impellers of different diameters in the same housing to expand the range of applications for the particular blower assembly. If a smaller diameter impeller is installed in a blower housing that was originally designed for use with a larger impeller, air leakage will increase between the blower housing and the smaller diameter impeller as compared to when the larger impeller is installed. By providing a momentum based interstitial seal on the smaller diameter impeller, the seal may orient the leakage direction substantially opposite to the direction of the velocity pressure of the air entering the blower assembly to reduce leakage between the blower housing and the smaller diameter impeller. Accordingly, by reducing the amount of air that escapes between the blower housing and the smaller diameter impeller, the seal may allow the blower assembly to generate an increased amount of airflow through the HVAC system, which may increase heat transfer between the airflow and heat exchange components of the HVAC system, thus increasing the overall efficiency of the HVAC system. Alternatively, the reduced leakage may reduce the fan power needed to move a given amount of airflow through the HVAC system to increase the overall efficiency of the HVAC system. In some embodiments, the blower assembly comprising the momentum based interstitial seal may be a component of an air handling unit. However, in some embodiments, the blower assembly comprising the momentum based interstitial seal may be a component of a gas-fired furnace. In yet other embodiments, the blower assembly comprising the momentum based interstitial seal may be a component of any other component and/or system of an HVAC system.

Referring now to FIG. 1, a schematic diagram of a heating, ventilation, and/or air conditioning (HVAC) system 100 is shown according to an embodiment of the disclosure. Most generally, HVAC system 100 comprises a heat pump system that may be selectively operated to implement one or more substantially closed thermodynamic refrigeration cycles to provide a cooling functionality (hereinafter “cooling mode”) and/or a heating functionality (hereinafter “heating mode”). The HVAC system 100, configured as a heat pump system, generally comprises an indoor unit 102, an outdoor unit 104, and a system controller 106 that may generally control operation of the indoor unit 102 and/or the outdoor unit 104.

Indoor unit 102 generally comprises an indoor air handling unit comprising an indoor heat exchanger 108, an indoor fan 110, an indoor metering device 112, and an indoor controller 124. The indoor heat exchanger 108 may generally be configured to promote heat exchange between refrigerant carried within internal tubing of the indoor heat exchanger 108 and an airflow that may contact the indoor heat exchanger 108 but that is segregated from the refrigerant. In some embodiments, the indoor heat exchanger 108 may comprise a plate-fin heat exchanger. However, in other embodiments, indoor heat exchanger 108 may comprise a microchannel heat exchanger and/or any other suitable type of heat exchanger.

The indoor fan 110 may generally comprise a variable speed blower comprising a blower housing, a blower impeller at least partially disposed within the blower housing, and a blower motor configured to selectively rotate the blower impeller. The indoor fan 110 may generally be configured to provide airflow through the indoor unit 102 and/or the indoor heat exchanger 108 to promote heat transfer between the airflow and a refrigerant flowing through the indoor heat exchanger 108. The indoor fan 110 may also be configured to deliver temperature-conditioned air from the indoor unit 102 to one or more areas and/or zones of a climate controlled structure. The indoor fan 110 may generally be configured as a modulating and/or variable speed fan capable of being operated at many speeds over one or more ranges of speeds. In other embodiments, the indoor fan 110 may be configured as a multiple speed fan capable of being operated at a plurality of operating speeds by selectively electrically powering different ones of multiple electromagnetic windings of a motor of the indoor fan 110. In yet other embodiments, however, the indoor fan 110 may be a single speed fan.

The indoor metering device 112 may generally comprise an electronically-controlled motor-driven electronic expansion valve (EEV). In some embodiments, however, the indoor metering device 112 may comprise a thermostatic expansion valve, a capillary tube assembly, and/or any other suitable metering device. In some embodiments, while the indoor metering device 112 may be configured to meter the volume and/or flow rate of refrigerant through the indoor metering device 112, the indoor metering device 112 may also comprise and/or be associated with a refrigerant check valve and/or refrigerant bypass configuration when the direction of refrigerant flow through the indoor metering device 112 is such that the indoor metering device 112 is not intended to meter or otherwise substantially restrict flow of the refrigerant through the indoor metering device 112.

Outdoor unit 104 generally comprises an outdoor heat exchanger 114, a compressor 116, an outdoor fan 118, an outdoor metering device 120, a reversing valve 122, and an outdoor controller 126. In some embodiments, the outdoor unit 104 may also comprise a plurality of temperature sensors for measuring the temperature of the outdoor heat exchanger 114, the compressor 116, and/or the outdoor ambient temperature. The outdoor heat exchanger 114 may generally be configured to promote heat transfer between a refrigerant carried within internal passages of the outdoor heat exchanger 114 and an airflow that contacts the outdoor heat exchanger 114 but that is segregated from the refrigerant. In some embodiments, outdoor heat exchanger 114 may comprise a plate-fin heat exchanger. However, in other embodiments, outdoor heat exchanger 114 may comprise a spine-fin heat exchanger, a microchannel heat exchanger, or any other suitable type of heat exchanger.

The compressor 116 may generally comprise a variable speed scroll-type compressor that may generally be configured to selectively pump refrigerant at a plurality of mass flow rates through the indoor unit 102, the outdoor unit 104, and/or between the indoor unit 102 and the outdoor unit 104. In some embodiments, the compressor 116 may comprise a rotary type compressor configured to selectively pump refrigerant at a plurality of mass flow rates. In alternative embodiments, however, the compressor 116 may comprise a modulating compressor that is capable of operation over a plurality of speed ranges, a reciprocating-type compressor, a single speed compressor, and/or any other suitable refrigerant compressor and/or refrigerant pump. In some embodiments, the compressor 116 may be controlled by a compressor drive controller 144, also referred to as a compressor drive and/or a compressor drive system.

The outdoor fan 118 may generally comprise an axial fan comprising a fan blade assembly and fan motor configured to selectively rotate the fan blade assembly. The outdoor fan 118 may generally be configured to provide airflow through the outdoor unit 104 and/or the outdoor heat exchanger 114 to promote heat transfer between the airflow and a refrigerant flowing through the outdoor heat exchanger 114. The outdoor fan 118 may generally be configured as a modulating and/or variable speed fan capable of being operated at a plurality of speeds over a plurality of speed ranges. In other embodiments, the outdoor fan 118 may comprise a mixed-flow fan, a centrifugal blower, and/or any other suitable type of fan and/or blower, such as a multiple speed fan capable of being operated at a plurality of operating speeds by selectively electrically powering different multiple electromagnetic windings of a motor of the outdoor fan 118. In yet other embodiments, the outdoor fan 118 may be a single speed fan. Further, in other embodiments, however, the outdoor fan 118 may comprise a mixed-flow fan, a centrifugal blower, and/or any other suitable type of fan and/or blower.

The outdoor metering device 120 may generally comprise a thermostatic expansion valve. In some embodiments, however, the outdoor metering device 120 may comprise an electronically-controlled motor driven EEV similar to indoor metering device 112, a capillary tube assembly, and/or any other suitable metering device. In some embodiments, while the outdoor metering device 120 may be configured to meter the volume and/or flow rate of refrigerant through the outdoor metering device 120, the outdoor metering device 120 may also comprise and/or be associated with a refrigerant check valve and/or refrigerant bypass configuration when the direction of refrigerant flow through the outdoor metering device 120 is such that the outdoor metering device 120 is not intended to meter or otherwise substantially restrict flow of the refrigerant through the outdoor metering device 120.

The reversing valve 122 may generally comprise a four-way reversing valve. The reversing valve 122 may also comprise an electrical solenoid, relay, and/or other device configured to selectively move a component of the reversing valve 122 between operational positions to alter the flowpath of refrigerant through the reversing valve 122 and consequently the HVAC system 100. Additionally, the reversing valve 122 may also be selectively controlled by the system controller 106 and/or an outdoor controller 126.

The system controller 106 may generally be configured to selectively communicate with an indoor controller 124 of the indoor unit 102, an outdoor controller 126 of the outdoor unit 104, and/or other components of the HVAC system 100. In some embodiments, the system controller 106 may be configured to control operation of the indoor unit 102 and/or the outdoor unit 104. In some embodiments, the system controller 106 may be configured to monitor and/or communicate with a plurality of temperature sensors associated with components of the indoor unit 102, the outdoor unit 104, and/or the ambient outdoor temperature. Additionally, in some embodiments, the system controller 106 may comprise a temperature sensor and/or a humidity sensor and/or may further be configured to control heating and/or cooling of zones associated with the HVAC system 100. In other embodiments, however, the system controller 106 may be configured as a thermostat for controlling the supply of conditioned air to zones associated with the HVAC system 100.

The system controller 106 may also generally comprise a touchscreen interface for displaying information and for receiving user inputs. The system controller 106 may display information related to the operation of the HVAC system 100 and may receive user inputs related to operation of the HVAC system 100. However, the system controller 106 may further be operable to display information and receive user inputs tangentially and/or unrelated to operation of the HVAC system 100. In some embodiments, however, the system controller 106 may not comprise a display and may derive all information from inputs from remote sensors and remote configuration tools.

In some embodiments, the system controller 106 may be configured for selective bidirectional communication over a communication bus 128. In some embodiments, portions of the communication bus 128 may comprise a three-wire connection suitable for communicating messages between the system controller 106 and one or more of the HVAC system 100 components configured for interfacing with the communication bus 128.

The indoor controller 124 may be carried by the indoor unit 102 and may generally be configured to receive information inputs, transmit information outputs, and/or otherwise communicate with the system controller 106, the outdoor controller 126, and/or any other device via the communication bus 128 and/or any other suitable medium of communication. In some embodiments, the indoor controller 124 may be configured to receive information related to a speed of the indoor fan 110, transmit a control output to an auxiliary heat source, transmit information regarding an indoor fan 110 volumetric flow-rate, communicate with and/or otherwise affect control over an air cleaner, and communicate with an indoor EEV controller. In some embodiments, the indoor controller 124 may be configured to communicate with an indoor fan 110 controller and/or otherwise affect control over operation of the indoor fan 110.

The outdoor controller 126 may be carried by the outdoor unit 104 and may be configured to receive information inputs, transmit information outputs, and/or otherwise communicate with the system controller 106, the indoor controller 124, and/or any other device via the communication bus 128 and/or any other suitable medium of communication. In some embodiments, the outdoor controller 126 may be configured to receive information related to an ambient temperature associated with the outdoor unit 104, information related to a temperature of the outdoor heat exchanger 114, and/or information related to refrigerant temperatures and/or pressures of refrigerant entering, exiting, and/or within the outdoor heat exchanger 114 and/or the compressor 116. In some embodiments, the outdoor controller 126 may be configured to transmit information related to monitoring, communicating with, and/or otherwise affecting control over the compressor 116, the outdoor fan 118, a solenoid of the reversing valve 122, a relay associated with adjusting and/or monitoring a refrigerant charge of the HVAC system 100, a position of the indoor metering device 112, and/or a position of the outdoor metering device 120. The outdoor controller 126 may further be configured to communicate with and/or control a compressor drive controller 144 that is configured to electrically power and/or control the compressor 116.

The HVAC system 100 is shown configured for operating in a so-called cooling mode in which heat is absorbed by refrigerant at the indoor heat exchanger 108 and heat is rejected from the refrigerant at the outdoor heat exchanger 114. In some embodiments, the compressor 116 may be operated to compress refrigerant and pump the relatively high temperature and high pressure compressed refrigerant from the compressor 116 to the outdoor heat exchanger 114 through the reversing valve 122 and to the outdoor heat exchanger 114. As the refrigerant is passed through the outdoor heat exchanger 114, the outdoor fan 118 may be operated to move air into contact with the outdoor heat exchanger 114, thereby transferring heat from the refrigerant to the air surrounding the outdoor heat exchanger 114. The refrigerant may primarily comprise liquid phase refrigerant and the refrigerant may flow from the outdoor heat exchanger 114 to the indoor metering device 112 through and/or around the outdoor metering device 120 which does not substantially impede flow of the refrigerant in the cooling mode. The indoor metering device 112 may meter passage of the refrigerant through the indoor metering device 112 so that the refrigerant downstream of the indoor metering device 112 is at a lower pressure than the refrigerant upstream of the indoor metering device 112. The pressure differential across the indoor metering device 112 allows the refrigerant downstream of the indoor metering device 112 to expand and/or at least partially convert to a two-phase (vapor and gas) mixture. The two-phase refrigerant may enter the indoor heat exchanger 108. As the refrigerant is passed through the indoor heat exchanger 108, the indoor fan 110 may be operated to move air into contact with the indoor heat exchanger 108, thereby transferring heat to the refrigerant from the air surrounding the indoor heat exchanger 108, and causing evaporation of the liquid portion of the two-phase mixture. The refrigerant may thereafter re-enter the compressor 116 after passing through the reversing valve 122.

To operate the HVAC system 100 in the so-called heating mode, the reversing valve 122 may be controlled to alter the flow path of the refrigerant, the indoor metering device 112 may be disabled and/or bypassed, and the outdoor metering device 120 may be enabled. In the heating mode, refrigerant may flow from the compressor 116 to the indoor heat exchanger 108 through the reversing valve 122, the refrigerant may be substantially unaffected by the indoor metering device 112, the refrigerant may experience a pressure differential across the outdoor metering device 120, the refrigerant may pass through the outdoor heat exchanger 114, and the refrigerant may re-enter the compressor 116 after passing through the reversing valve 122. Most generally, operation of the HVAC system 100 in the heating mode reverses the roles of the indoor heat exchanger 108 and the outdoor heat exchanger 114 as compared to their operation in the cooling mode.

Referring now to FIG. 2, a schematic diagram of an air circulation path 200 of the HVAC system 100 of FIG. 1 is shown according to an embodiment of the disclosure. The HVAC system 100 of FIG. 1 may generally comprise an indoor fan 110 configured to circulate and/or condition air through a plurality of zones 202, 204, 206 of a structure 201. It will be appreciated that while three zones 202, 204, 206 are shown, any number of zones may be present in the structure 201. The air circulation path 200 of the HVAC system 100 may generally comprise a first zone supply duct 208, a second zone supply duct 210, a third zone supply duct 212, a first zone return duct 214, a second zone return duct 216, a third zone return duct 218, a main return duct 220, a main supply duct 222, a plurality of zone dampers 224, and an indoor unit 102 comprising an indoor heat exchanger 108, and an indoor fan 110. In some embodiments, the HVAC system 100 may also comprise a heat source 150. In some embodiments, the heat source 150 may comprise electrical resistance heating elements installed in the indoor unit 102. However, in other embodiments, the heat source 150 may comprise a furnace configured to burn fuel such as, but not limited to, natural gas, heating oil, propane, and/or any other suitable fuel, to generate heat. Further, in embodiments where the heat source 150 comprises a furnace, it will be appreciated that the furnace may also comprise an inducer blower substantially similar to the indoor fan 110 that may be configured to circulate an air-fuel mixture through the furnace.

Additionally, the HVAC system 100 may further comprise a zone thermostat 158 and a zone sensor 160. In some embodiments, a zone thermostat 158 may communicate with the system controller 106 and may allow a user to control a temperature setting, a humidity setting, and/or other environmental setting for the zone 202, 204, 206 in which the zone thermostat 158 is located. Further, the zone thermostat 158 may communicate with the system controller 106 to provide temperature, humidity, and/or other environmental feedback regarding the zone 202, 204, 206 in which the zone thermostat 158 is located. In some embodiments, a zone sensor 160 may also communicate with the system controller 106 to provide temperature, humidity, and/or other environmental feedback regarding the zone 202, 204, 206 in which the zone sensor 160 is located. Further, although only one zone thermostat 158 and one zone sensor 160 are shown, each of the zones 202, 204, 206 may comprise a zone thermostat 158 and/or a zone sensor 160.

The system controller 106 may be configured for bidirectional communication with any zone thermostat 158 and/or zone sensor 160 so that a user may, using the system controller 106, monitor and/or control any of the HVAC system 100 components regardless of which zones 202, 204, 206 the zone thermostat 158 and/or zone sensor 160 may be associated. Further, each system controller 106, each zone thermostat 158, and each zone sensor 160 may comprise a temperature sensor and/or a humidity sensor. As such, it will be appreciated that structure 201 is equipped with a plurality of temperature sensors and/or humidity sensors in the plurality of different zones 202, 204, 206. In some embodiments, a user may effectively select which of the plurality of temperature sensors and/or humidity sensors is used to control operation of the HVAC system 100. Thus, when at least one of the system controller 106, the zone thermostat 158, and the zone sensor 160 determines that a temperature and/or humidity of an associated zone has fallen outside either the temperature setting or the humidity setting, respectively, the system controller 106 may operate the HVAC system 100 in either the cooling mode or the heating mode to provide temperature conditioned air to at least one of the zones 202, 204, 206. Additionally the system controller 106 may also activate and/or operate the heat source 150 to provide heat and/or dehumidification while operating in the heating mode.

In operation, the indoor fan 110 may be configured to generate an airflow through the indoor unit 102 and/or the heat source 150 to deliver conditioned air from an air supply opening in the indoor unit 102, through the main supply duct 222, and to each of the plurality of zones 202, 204, 206 through each of the first zone supply duct 208, the second zone supply duct 210, and the third zone supply duct 212, respectively. Additionally, each of the first zone supply duct 208, the second zone supply duct 210, and the third zone supply duct 212 may comprise a zone damper 224 that regulates the airflow to each of the zones 202, 204, 206. In some embodiments, the zone dampers 224 may regulate the flow to each zone 202, 204, 206 in response to a temperature or humidity sensed by at least one temperature sensor and/or humidity sensor carried by at least one of the system controller 106, the zone thermostat 158, and the zone sensor 160.

Air from each zone 202, 204, 206 may return to the main return duct 220 through each of the first zone return duct 214, the second zone return duct 216, and the third zone return duct 218. From the main return duct 220, air may return to the indoor unit 102 through an air return opening in the indoor unit 102. Air entering the indoor unit 102 through the air return opening may then be conditioned for delivery to each of the plurality of zones 202, 204, 206 as described above. Circulation of the air in this manner may continue repetitively until the temperature and/or humidity of the air within the zones 202, 204, 206 conforms to a target temperature and/or a target humidity as required by at least one of the system controller 106, the zone thermostat 158, and/or the zone sensor 160.

Referring now to FIGS. 3 and 4, an oblique view and an orthogonal side view of a blower assembly 300 are shown, respectively, according to an embodiment of the disclosure. Blower assembly 300 may generally be substantially similar to the indoor fan 110 of FIGS. 1 and 2 and be installed in an HVAC system 100 in a substantially similar manner to that of indoor fan 110 of FIGS. 1 and 2. Blower assembly 300 generally comprises a blower housing 302 comprising a left inlet 304, a right inlet 306, and an outlet 308 disposed through a blower deck 310. Blower assembly 300 also comprises a motor 312 comprising a shaft upon which an impeller 314 comprising a plurality of fan blades 316 disposed about the impeller 314 is mounted. Additionally, the motor 312 may be secured to the blower housing 302 via a plurality of mounts 318. A primary function of the blower housing 302 is to receive at least a portion of each of the motor 312 and the impeller 314 while also defining an airflow path between each of the opposing left inlet 304 and right inlet 306 of the blower housing 302 and the outlet 308 of the blower housing 302. Further, it will be appreciated that in some embodiments, the blower deck 310 of the blower housing 302 may be used to mount the blower assembly 300.

In operation, the motor 312 may be operated to selectively rotate the impeller 314 about an axis of rotation 320 of the shaft of the motor 312. The selective rotation of the impeller 314 and the configuration of the blades 316 of the impeller 314 may generally draw an intake of air into the blower housing 302 through the left inlet 304 and/or the right inlet 306 and create a static pressure within the blower housing 302. The buildup of static pressure within the blower housing 302 may generate an airflow through the blower housing 302 by forcing the air received via the left inlet 304 and/or the right inlet 306 through the blower housing 302 along an internal flow path of the blower housing 302, whereby the airflow may exit the blower housing 302 through the outlet 308 of the blower housing 302. After leaving the outlet 308 of the blower housing 302, the airflow may selectively be passed through components of the HVAC system 100 of FIGS. 1 and 2.

Referring now to FIG. 5, a partial cross-sectional view of the blower assembly 300 of FIGS. 3 and 4 taken along cutting line A-A of FIG. 4 is shown according to an embodiment of the disclosure. In this embodiment, impeller 314 may generally represent a conventional sized impeller designed for proper fitment and use in the blower housing 302. Thus, the blower housing 302 may have been originally designed to be used with impeller 314. As stated, when the impeller 314 is rotated about the axis of rotation 320 of the shaft of the motor 312, the blades 316 of the impeller 314 may generally draw an intake of air into the blower housing 302 through the left inlet 304 and/or the right inlet 306 in a primary incoming air direction 322. In some embodiments, the primary incoming air direction 322 may be substantially parallel and/or axially aligned with the axis of rotation 320 of the shaft of the motor 312.

The impeller 314 imparts pressure to the airstream passing through it, at least some of which will take the form of static pressure within the blower housing 302. The difference in static pressure between the interior of the blower housing 302 and the blower inlets 304, 306 may cause and/or drive leakage of air between the blower housing 302 and blower inlets 304, 306. In this embodiment, the leakage may exit the blower housing 302 between the impeller 314 and ends 305 of the blower housing 302 that form each of the left inlet 304 and the right inlet 306 in a primary leakage direction 324. In this embodiment, the primary leakage direction 324 may be directed at least partially towards each of the left inlet 304 and the right inlet 306. As such, the primary leakage direction 324 may be approximately perpendicular to the primary incoming air direction 322 of the intake of air entering each of the left inlet 304 and the right inlet 306. This leakage represents a blower performance loss as it reduces the net amount of work accomplished by the blower.

Referring now to FIG. 6, a partial cross-sectional view of a blower assembly 400 taken along cutting line A-A of the blower assembly 300 of FIG. 4 is shown according to another embodiment of the disclosure. Blower assembly 400 may generally be substantially similar to blower assembly 300 and be configured to operate in a substantially similar manner to blower assembly 300. However, while blower assembly 400 comprises substantially similar components as blower assembly 300, blower assembly 400 comprises a smaller diameter impeller 414 comprising a plurality of fan blades 416 disposed about the smaller diameter impeller 414 instead of the impeller 314 of blower assembly 300. Accordingly, it will be appreciated that the smaller diameter impeller 414 comprises an overall smaller diameter than the conventional sized impeller 314. In some embodiments, the smaller diameter impeller 414 may extend at least partially beyond the ends 305 of the blower housing 302 and be disposed at least partially radially into the inlets 304, 306 of the blower housing 302. Further, it will be appreciated that in some embodiments, the smaller diameter impeller 414 comprises an overall diameter smaller than the diameter of each of the inlets 304, 306. As such, it will be appreciated that blower housing 302 may be configured to operate with either impeller 314 or smaller diameter impeller 414.

Furthermore, the smaller diameter impeller 414 may generally increase the gap between the ends 305 of each of the left inlet 304 and the right inlet 306 of the blower housing 302 and the smaller diameter impeller 414. In some instances, the larger gap between the ends 305 of each of the left inlet 304 and the right inlet 306 of the blower housing 302 and the smaller diameter impeller 414 may be caused at least partially by the entirety of the smaller diameter impeller 414 being located within the left inlet 304 and the right inlet 306. Thus, in some embodiments, no portion of the smaller diameter impeller 414 may comprise a larger diameter than the diameter of the left inlet 304 and/or the right inlet 306.

Similarly to blower assembly 300, when blower assembly 400 is operated, work done on the air stream passing through the impeller 414 may create a static pressure within the blower housing 302. The pressure buildup, both static and velocity pressure, within the blower housing 302 may generate an airflow through the blower housing 302 by forcing the air received via the left inlet 304 and/or the right inlet 306 through the blower housing 302 along an internal flow path of the blower housing 302, whereby the airflow may exit the blower housing 302 through the outlet 308 of the blower housing 302. Additionally, the static pressure within the blower housing 302 may cause and/or drive leakage between the blower housing 302 and the smaller diameter impeller 414. In this embodiment, the leakage may exit the blower housing 302 between the smaller diameter impeller 414 and the ends 305 of the blower housing 302 that form each of the left inlet 304 and the right inlet 306 in a primary leakage direction 424.

Since the gap between the ends 305 of each of the left inlet 304 and the right inlet 306 of the blower housing 302 and the smaller diameter impeller 414 is increased by the smaller diameter impeller 414, leakage from the blower housing 302 may also be increased. In some embodiments, the primary leakage direction 424 may generally be roughly orthogonal to the primary incoming air direction 322. As such, the primary leakage direction 424 may roughly form about a ninety degree angle with the primary incoming air direction 322 of the intake of air entering each of the left inlet 304 and the right inlet 306.

Referring now to FIG. 7, a partial cross-sectional view of a blower assembly 500 taken along cutting line A-A of the blower assembly 300 of FIG. 4 is shown according to yet another embodiment of the disclosure. Blower assembly 500 may generally be substantially similar to blower assembly 400 and be configured to operate in a substantially similar manner to blower assembly 400. However, while blower assembly 500 comprises substantially similar components as blower assembly 400, blower assembly 500 comprises the smaller diameter impeller 414 of blower assembly 400 and a peripheral flange 505 disposed about the smaller diameter impeller 414. The peripheral flange 505 generally comprises a base 504 and a flange 506 extending from the base 504 to collectively form an outer circular rim of the smaller diameter impeller 414 to which the blades 416 of the smaller diameter impeller 414 are affixed. Accordingly, the leakage flow direction 524 of blower assembly 500 is substantially counter to the primary incoming air direction 322. As such, momentum of the inlet flow entering the inlets 304, 306 in the primary incoming air direction 322 will reduce leakage from the blower housing 302 by forming a momentum based interstitial seal 502 that will improve the performance of the blower. It will be appreciated that blower housing 302 may be configured to operate with either impeller 314, smaller diameter impeller 414, or smaller diameter impeller 414 with the momentum based interstitial seal 502.

The momentum based interstitial seal 502 may generally comprise and/or be formed by the peripheral flange 505 and the blower inlet orifice 305. Additionally, the momentum based interstitial seal 502 may be formed by orienting the peripheral flange 505 and the ends 305 of the blower housing 302 such that the leakage flow direction 524 of blower assembly 500 is substantially counter to the primary incoming air direction 322. In some embodiments, the flange 506 may extend substantially parallel to the axis of rotation 320 of the shaft of the motor 312. More specifically, at least in some embodiments, the blades 416 may be affixed to the base 504 of the peripheral flange 505 that forms a rim about the smaller diameter impeller 414 to which the blades 416 are affixed. In some embodiments, the blades 416 and the peripheral flange 505 may be formed from a sheet metal compound and be crimped, welded, molded around, and/or otherwise joined to collectively form the smaller diameter impeller 414. However, in other embodiments, the peripheral flange 505 may be formed from an elastomeric compound, plastic, and/or any other material and be joined to the blades 416 of the smaller diameter impeller 414 and/or an outer surface of an existing impeller via adhesive, molding, rivets, and/or any other fastening means to collectively form the smaller diameter impeller 414.

Similarly to blower assembly 400, when blower assembly 500 is operated, an intake of air into the blower housing 302 may create a static pressure within the blower housing 302. The buildup of pressure, both static and velocity, within the blower housing 302 may generate an airflow through the blower housing 302 by forcing the air received via the left inlet 304 and/or the right inlet 306 through the blower housing 302 along an internal flow path of the blower housing 302, whereby the airflow may exit the blower housing 302 through the outlet 308 of the blower housing 302. Additionally, the static pressure within the blower housing 302 may also cause and/or drive leakage between the blower housing 302 and the smaller diameter impeller 414. In this embodiment, the leakage may exit the blower housing 302 through the momentum based interstitial seal 502 between the peripheral flange 505 of the smaller diameter impeller 414 and the ends 305 of the blower housing 302 that form each of the left inlet 304 and the right inlet 306 in a primary leakage direction 524. In some embodiments, the momentum based interstitial seal 502 may direct leakage flow along direction 524 which is counter to the inlet flow direction 322 such that the velocity pressure of the inlet flow in the primary incoming air direction 322 may, in part, reduce leakage between the blower housing 302 and the smaller diameter impeller 414.

However, the momentum based interstitial seal 502 is configured to direct the leakage in the primary leakage direction 524 that is substantially away from each of the left inlet 304 and the right inlet 306. Thus, in some embodiments, the primary leakage direction 524 may at least partially oppose the primary incoming air direction 322. As such, in some embodiments, the primary leakage direction 524 may form an obtuse angle with the primary incoming air direction 322 of the intake of air entering each of the left inlet 304 and the right inlet 306. In other embodiments, the momentum based interstitial seal 502 may configured to direct the leakage in the primary leakage direction 524 that is substantially opposite to the primary incoming air direction 322 entering each of the left inlet 304 and the right inlet 306. Accordingly, the momentum based interstitial seal 502 of blower assembly 500 changes the roughly orthogonal primary leakage direction 424 of blower assembly 400 to an at least partially opposing primary leakage direction 524 with respect to the primary incoming air direction 322. Thus, it will be appreciated that the momentum based interstitial seal 502 is configured to orient the primary leakage direction 524 against the primary incoming air direction 322.

By the momentum based interstitial seal 502 orienting the primary leakage direction 524 against the primary incoming air direction 322, the velocity pressure created by the incoming airflow may oppose the static pressure within the blower housing 302 that is attempting to drive leakage. Further, since the incoming airflow is entering the blower housing 302 through the inlets 304, 306 at a high velocity, the static pressure cannot easily overcome the velocity pressure created by the incoming airflow. Accordingly, the momentum based interstitial seal 502 may be configured to employ the velocity pressure of the incoming air entering the blower housing 302 through each of the left inlet 304 and the right inlet 306 in the primary incoming air direction 322 to substantially counteract and/or overcome the static pressure within the discharge side of blower housing 302 that drives the leakage. Since the static pressure within the blower housing 302 cannot easily overcome the velocity pressure of the incoming airflow, the momentum based interstitial seal 502 may substantially reduce and/or eliminate leakage between the blower housing 302 and the smaller diameter impeller 414 and/or the momentum based interstitial seal 502 of the smaller diameter impeller 414. This is due, at least in part, to the primary leakage direction 524 being against the primary incoming air direction 322, and to the static pressure driving the leakage not overcome the high velocity pressure of the incoming airflow. Therefore, the momentum based interstitial seal 502 orients the primary leakage direction 524 against the primary incoming air direction 322 to employ the incoming airflow entering the blower housing 302 to counteract the static pressure driving leakage to substantially reduce and/or eliminate leakage from the blower housing 302.

In some embodiments, the blower assembly 500 may reduce leakage by at least about 10%, at least about 20%, at least about 30%, at least about 33%, at least about 35%, at least about 40%, at least about 50%, and/or at least about 60% as compared to a blower assembly comprising a smaller diameter impeller, such as blower assembly 400 that comprises smaller diameter impeller 414, in a conventional sized blower housing, such as blower housing 302. Additionally, in some embodiments, the reduction in leakage between the blower housing 302 and the smaller diameter impeller 414 and/or the momentum based interstitial seal 502 of the smaller diameter impeller 414 may provide an increased blower assembly 500 efficiency by at least about 1%, at least about 2%, at least about 3%, at least about 5%, at least about 10%, and/or at least about 15% as compared to a blower assembly comprising a smaller diameter impeller, such as blower assembly 400 that comprises smaller diameter impeller 414, in a conventional sized blower housing, such as blower housing 302.

Furthermore, it should be understood that the disclosed systems and methods may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented. In some embodiments, a blower assembly 500 comprising a smaller diameter impeller 414 and a momentum based interstitial seal 502 may be a component of an air handling unit, such as indoor unit 102 of HVAC system 100 of FIGS. 1 and 2. However, in some embodiments, the blower assembly 500 may be a component of a gas-fired furnace, such as the heat source 150 of HVAC system 100 of FIG. 2. In yet other embodiments, the blower assembly 500 may be a component of any other component and/or system of an HVAC system 100 that requires an airflow (e.g. geothermal heat pump systems, automotive HVAC systems, and/or any other system, device, and/or component that requires a fan to generate an airflow).

Referring now to FIG. 8, a flowchart of a method 600 of operating a blower assembly is shown according to an embodiment of the disclosure. The method 600 may begin at block 602 by providing a blower assembly comprising a blower housing and an impeller comprising a momentum based interstitial seal. The method 600 may continue at block 604 by operating a motor of the blower assembly to rotate the impeller about an axis of rotation to draw an incoming airflow into at least one air inlet of the blower housing in a primary incoming air direction. The method 600 may continue at block 606 by orienting leakage between the blower housing and the impeller against the incoming airflow entering the at least one air inlet. In some embodiments, the orienting leakage between the blower housing and the impeller against an incoming airflow entering the at least one air inlet reduces leakage between the blower housing and the impeller. Additionally, in some embodiments, reducing leakage between the blower housing and the impeller is accomplished by the momentum based interstitial seal employing a velocity pressure of the incoming airflow to overcome a static pressure within the blower housing that drives leakage and that is created by the operating the motor of the blower assembly to rotate the impeller about the axis of rotation to draw the incoming airflow into at least one air inlet of the blower housing in a primary incoming air direction.

At least one embodiment is disclosed and variations, combinations, and/or modifications of the embodiment(s) and/or features of the embodiment(s) made by a person having ordinary skill in the art are within the scope of the disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, R₁, and an upper limit, R_u, is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=R₁+k*(R_u−R₁), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . , 50 percent, 51 percent, 52 percent, . . . , 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Unless otherwise stated, the term “about” shall mean plus or minus 10 percent of the subsequent value.

Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Use of the term “optionally” with respect to any element of a claim means that the element is required, or alternatively, the element is not required, both alternatives being within the scope of the claim. Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of Accordingly, the scope of protection is not limited by the description set out above but is defined by the claims that follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention.

Momentum Based Blower Interstitial Seal

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