The various embodiments relate generally to heating, ventilation, and air-conditioning (HVAC) technologies and, more specifically, to a sound-reducing exhaust air system.
In industrial or commercial settings, such as warehouses, factories, and data centers, exhaust air is often removed or discarded from the facility by one or more rooftop exhaust units. In larger facilities, many such exhaust units can be required to provide sufficient exhaust capabilities. For example, these units can be positioned at various locations along the roof of a building depending upon the heating and cooling load and/or other exhaust requirements of the building.
One drawback of rooftop exhaust units, particularly when employed in large numbers, is noise generation. A typical exhaust unit includes one or more fans that discharge high volumes of air from a building, but also produce significant fan noise. Further, the elevated position of rooftop exhaust units ensures that any fan noise generated can be perceived at a greater distance, and therefore can be more impactful than fan noise generated at ground level.
Another drawback of rooftop exhaust units is power use. Energy consumption is an important concern with large commercial and industrial buildings, especially for power-intensive facilities like data centers. Oftentimes, a rooftop exhaust unit operates continuously, and consequently can consume a large quantity of power. Further, in many applications, such as a data center, a large number of rooftop exhaust units are employed for a single building. Therefore, in such applications the energy consumed by a single rooftop exhaust unit is multiplied many times.
Yet another drawback of rooftop exhaust units is water ingress. Each rooftop exhaust unit requires a roof penetration to draw exhaust air from within a building. As a result, each unit is associated with a possible route by which water can enter the building. This is particularly true for exhaust systems having an upblast configuration, in which exhaust air is discharged upward. As noted previously, in many applications a large number of rooftop exhaust units are employed for a single building. Therefore, any leak path associated with a particular model of rooftop exhaust unit is instantiated across the roof of the building. In some instances, such as in a data center application, even a single such roof leak can be catastrophic.
As the foregoing illustrates, what is needed in the art are more effective techniques for exhausting air from rooftop units.
According to various embodiments, an exhaust air system includes: a housing with an air inlet that allows air to enter the housing and an air outlet that allows air to exit the housing; a vertical array of multiple fans that includes at least one upper fan and at least one lower fan, wherein the at least one upper fan is disposed above the at least one lower fan and is positioned with a horizontal offset in a horizontal direction from the at least one lower fan so that the at least one upper fan is closer to the air inlet in the horizontal direction than the at least one lower fan; and a deflector plate disposed within an inlet air plenum for the vertical array of multiple fans, wherein the deflector plate facilitates a flow of air entering the housing via the air inlet toward the at least one upper fan.
At least one technical advantage of the disclosed design relative to the prior art is that the disclosed design enables quieter operation of rooftop exhaust units for a given quantity of exhaust air flow. Another advantage of the disclosed design is that a given quantity of air can be exhausted from a building by a rooftop exhaust unit with less internal pressure drop being generated within the rooftop exhaust unit. As a result, significantly less power is consumed to exhaust the same quantity of air. A further advantage is that the potential for water ingress through a rooftop exhaust unit is greatly reduced by the elimination of a direct vertical path between an air inlet and an air outlet of the rooftop exhaust unit. These technical advantages provide one or more technological advancements over prior art approaches.
So that the manner in which the above recited features of the various embodiments can be understood in detail, a more particular description of the inventive concepts, briefly summarized above, may be had by reference to various embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of the inventive concepts and are therefore not to be considered limiting of scope in any way, and that there are other equally effective embodiments.
Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
In the following description, numerous specific details are set forth to provide a more thorough understanding of the various embodiments. However, it will be apparent to one skilled in the art that the inventive concepts may be practiced without one or more of these specific details.
As noted above, issues associated with conventional rooftop exhaust units include noise generation, energy consumption, and water ingress. According to various embodiments, an exhaust system is configured to have reduced internal pressure drop and noise generation in comparison to a conventional rooftop exhaust unit. Further, the herein-described exhaust system reduces the potential for water ingress via a horizontal offset between an air inlet of the exhaust system and an upblast air outlet of the exhaust system. An embodiment of one such air-handling system is described below in conjunction with
In the embodiment illustrated in
Exhaust air system 100 can be powered by various types of power sources, such as a diesel generator and/or an electrical power source. According to various embodiments described herein, for a given quantity of exhaust air discharged via, the power consumption of exhaust air system 100 relative to a conventional exhaust system is significantly less. This is due to reduced pressure drop within exhaust air system 100 and enhanced airflow that equalizes the workload between the fans of a multiple-fan array within exhaust air system 100.
In the embodiment illustrated in
Outlet air plenum 122 is a region of exhaust air system 100 that is fluidly coupled to air outlet 102 and inlet air plenum 123 is a region of exhaust air system 100 that is fluidly coupled to air inlet 101. As shown, outlet air plenum 122 is disposed downstream of vertical fan array 130 and receives discharge air 302 discharged by upper fans 331 and lower fans 332 of vertical fan array 130. Conversely, inlet air plenum 123 is disposed upstream of vertical fan array 130 and receives incoming air 303 drawn into exhaust air system 100 by upper fans 331 and lower fans 332 of vertical fan array 130.
In some embodiments, outlet air plenum 122 is configured as a sound-absorbing chamber. In such embodiments, outlet air plenum 122 includes one or more sound-attenuation walls 321 that absorb or otherwise attenuate fan noise entering outlet air plenum 122 from vertical fan array 130, thereby significantly reducing fan noise exiting exhaust air system 100 via air outlet 102. In some embodiments, sound-attenuation walls 321 include the side walls 125 or portions of side walls 125 forming outlet air plenum 122. In some embodiments, sound-attenuating walls 321 include a portion 324 of top wall 124. In some embodiments, the one or more sound-attenuation walls 321 include a physical configuration for attenuating sound or a material for attenuating sound. For example, in some embodiments, the one or more sound-attenuation walls 321 include a perforated surface, sound-dampening slats, and/or an array of sound-absorbing shapes disposed on the interior surfaces of wound-attenuation walls 321, such as pyramids, projections, ridges, cavities, and/or the like. Alternatively or additionally, in such embodiments, the one or more sound-attenuation walls 321 include one or more materials for attenuating sound. Examples of such materials include foam, sponge, an acoustic surface texture, stone wool, wood fiber or wood fiber board, and cork. In some embodiments, sound-attenuation walls 321 are lined with such materials, and in other embodiments, such materials are integrated into sound-attenuation walls 321.
In the embodiment illustrated in
In the embodiment illustrated in
Returning to
Vertical fan array 130 is a vertical array of multiple fans that includes at least one upper fan 331 and at least one lower fan 332, where the at least one upper fan is disposed above and adjacent to the at least one lower fan 332. In the embodiment illustrated in
According to various embodiments, upper fans 331 are positioned with a horizontal offset 334 in horizontal direction 313 from lower fans 332. Thus, in such embodiments, upper fan 331 are closer to air inlet 101 in horizontal direction 313 than lower fans 332. In such embodiments, such positioning of upper fans 331 relative to lower fans 332 can equalize the workload between upper fans 331 and lower fans 332. Specifically, the presence of horizontal offset 334 between upper fans 331 and lower fans 332 increases the portion of air flowing through upper fans 331 relative to lower fans 332. As a result, for a given total flow of discharge air 302 discharged by upper fans 331 and lower fans 332, less pressure drop is generated within exhaust air system 100 during operation. By contrast, when upper fans 331 are vertically aligned with lower fans 332, upper fans 331 are “starved” of air relative to lower fans 332, and therefore cannot contribute to the flow of discharge air 302 as effectively as lower fans 332. It is noted that the magnitude of horizontal offset 334 is based on multiple factors, including the size and shape of inlet air plenum 123, the size and shape of air inlet 101, the diameter of upper fans 331 and lower fans 332, the target volume of discharge air 302 to be discharged from exhaust air system 100, the size and shape of deflector plate 150, the position of deflector plate 150 within inlet air plenum 123, and/or the like.
Deflector plate 150 is positioned within inlet air plenum 123 to modify the flow of incoming air 303 in a way that can further equalize the workload between upper fans 331 and lower fans 332. According to various embodiments, the presence of deflector plate 150 upstream of upper fans 331 and lower fans 332 increases the portion of air flowing through upper fans 331 relative to lower fans 332. Specifically, deflector plate 150 at least partially deflects incoming air 303 after entering air inlet 101 from vertical direction 312 to horizontal direction 311. As a result, for a given total flow of discharge air 302 discharged by upper fans 331 and lower fans 332, less pressure drop is generated within exhaust air system 100 during operation.
In the embodiment illustrated in
In the embodiment illustrated in
Returning to
In an example embodiment, vertical fan array 130 is implemented as a 2×2 array and exhaust air system 100 is configured to provide a specified air flow of 68,000 SCFM at standard temperature and pressure (60° F., 50% relative humidity, 14.696 pounds per square inch, 38.5 Grains/lb dry air, and a density of 0.0761 lbs/ft3). In the example embodiments, pressure drop across exhaust air system 100 can be reduced to approximately 0.4 inches water gage (external static pressure) to improve power consumption and reduce the horsepower requirements of motors powering the unit.
In sum, the various embodiments shown and provided herein set forth an exhaust air system with a vertical fan array that enables quieter operation and generates less pressure drop than conventional exhaust air systems. The exhaust system includes a deflector plate disposed in an air inlet plenum that deflects incoming air toward upper fans in the vertical fan array. In addition, the upper fans of the vertical fan array are horizontally offset from the lower fans of the vertical fan array to further increase the portion of air flowing through the upper fans relative to the lower fans. The exhaust system further includes a turning vane array disposed in an air outlet plenum that directs discharge air from a horizontal direction to a vertical direction.
At least one technical advantage of the disclosed design relative to the prior art is that the disclosed design enables quieter operation of rooftop exhaust units for a given quantity of exhaust air flow. Another advantage of the disclosed design is that a given quantity of air can be exhausted from a building by a rooftop exhaust unit with less internal pressure drop being generated within the rooftop exhaust unit. As a result, significantly less power is consumed to exhaust the same quantity of air. A further advantage is that the potential for water ingress through a rooftop exhaust unit is greatly reduced by the elimination of a direct vertical path between an air inlet and an air outlet of the rooftop exhaust unit. These technical advantages provide one or more technological advancements over prior art approaches.
Any and all combinations of any of the claim elements recited in any of the claims and/or any elements described in this application, in any fashion, fall within the contemplated scope of the present invention and protection.
The descriptions of the various embodiments have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments.
While the preceding is directed to embodiments of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
This application claims priority benefit of the U.S. Provisional Patent Application titled, “SOUND-REDUCING ROOF MOUNTED EXHAUST UNIT” filed on Jul. 13, 2023 and having Ser. No. 63/526,584. The subject matter of this related application is hereby incorporated herein by reference.
Number | Date | Country | |
---|---|---|---|
63526584 | Jul 2023 | US |