US20230235918A1 - Field-assembled air conveyance apparatus, and systems and methods utilizing air conveyance apparatus - Google Patents

Field-assembled air conveyance apparatus, and systems and methods utilizing air conveyance apparatus Download PDF

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Publication number
US20230235918A1
US20230235918A1 US18/130,700 US202318130700A US2023235918A1 US 20230235918 A1 US20230235918 A1 US 20230235918A1 US 202318130700 A US202318130700 A US 202318130700A US 2023235918 A1 US2023235918 A1 US 2023235918A1
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United States
Prior art keywords
transition
air
conveyance apparatus
panels
air conveyance
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Pending
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US18/130,700
Inventor
Claudio Santini
Nicholas Raissis
Fadi Hurtubise
Gregg W. Burnett
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Individual
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Individual
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Priority claimed from US17/643,226 external-priority patent/US11892190B1/en
Application filed by Individual filed Critical Individual
Priority to US18/130,700 priority Critical patent/US20230235918A1/en
Publication of US20230235918A1 publication Critical patent/US20230235918A1/en
Pending legal-status Critical Current

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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24FAIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F13/00Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening
    • F24F13/28Arrangement or mounting of filters
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24FAIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F13/00Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening
    • F24F13/20Casings or covers
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24FAIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F8/00Treatment, e.g. purification, of air supplied to human living or working spaces otherwise than by heating, cooling, humidifying or drying
    • F24F8/10Treatment, e.g. purification, of air supplied to human living or working spaces otherwise than by heating, cooling, humidifying or drying by separation, e.g. by filtering
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24FAIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F8/00Treatment, e.g. purification, of air supplied to human living or working spaces otherwise than by heating, cooling, humidifying or drying
    • F24F8/20Treatment, e.g. purification, of air supplied to human living or working spaces otherwise than by heating, cooling, humidifying or drying by sterilisation
    • F24F8/22Treatment, e.g. purification, of air supplied to human living or working spaces otherwise than by heating, cooling, humidifying or drying by sterilisation using UV light
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24FAIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F8/00Treatment, e.g. purification, of air supplied to human living or working spaces otherwise than by heating, cooling, humidifying or drying
    • F24F8/10Treatment, e.g. purification, of air supplied to human living or working spaces otherwise than by heating, cooling, humidifying or drying by separation, e.g. by filtering
    • F24F8/108Treatment, e.g. purification, of air supplied to human living or working spaces otherwise than by heating, cooling, humidifying or drying by separation, e.g. by filtering using dry filter elements

Definitions

  • HVAC heating, ventilating and/or air conditioning
  • the inlet dimensions of the coil may not be the same dimensions as the outlet of the furnace.
  • SEER Seasonal Energy Efficiency Ratio
  • the outlet of the furnace is smaller than the inlet of the coil and a reduction in air flow is created such that SEER ratings are not achieved.
  • prescribed servicing of aforementioned appliances are restricted and in some cases not achievable, thus requiring a full disassembly/separation of the appliances to gain access to needed internal components.
  • Transitions, or the like, used to join an air handling unit, such as a furnace, and another unit, such as the aforementioned air conditioning evaporator coil, are formed from sheet metal in an off-site shop and transported to a job site. Shipping or other transport of such an open-ended transition, or the like, is problematic in that it is bulky and structurally unsound, alone. For example, it is often necessary to mount the transition on a palette which greatly increases shipping or transportation costs.
  • Static pressure can be defined as the resistance to airflow within the ductwork in an HVAC system and in an electric air-handler or heat-pump and other components.
  • Static pressure For an HVAC system to operate efficiently, air must be pushed through the air ducts with greater intensity than the static pressure level within the system. If the HVAC system does not meet this condition, airflow can be adversely restricted.
  • the lower the static pressure the better the efficiency.
  • a static pressure of 0.5 inches per water column (in. W.C.) or lower is ideal.
  • a static pressure greater than 0.5 in. W.C. can result in several problems.
  • the restricted airflow caused by a larger static pressure can result in noisy heating and cooling equipment.
  • the higher the static pressure the louder the noise in the HVAC system will be.
  • impaired airflow can result in undesirable hot spots, cold spots, or air that hovers above a register. This is because when static pressure is high, the HVAC system tends to move too much air, or an insufficient amount of, air per ton.
  • inefficiency caused by high static pressures can place undue strain on the compressor, the blower motor, and/or other components of the HVAC system, because the system must work harder to compensate for poor airflow.
  • the undue strain can lead to premature equipment failure and hence expensive repairs.
  • inefficiency can also increase the amount of energy needed to run the HVAC system, resulting in higher electricity bills.
  • high static pressures may also adversely affect the refrigerant when charging the unit, and may cause air filters to load up with particulates faster than normal.
  • HVAC systems may use one or more air filters to remove impurities such as dust, pet dander or even bacteria from the air flowing through the system.
  • an air filter has been positioned in an HVAC system at a location abutting the base of the electric air handling unit. In that location, the air filter is close to or adjacent the evaporator coil in the air handling unit. This position of the air filter relative to the evaporator coil increases the static pressure in the HVAC system. This is especially true when the dimensions of the air filter are greater than the dimensions of the inlet of the air handler, e.g., when the perimeter of the filter is greater than the perimeter of the inlet. The differences in size create an offset between the air filter and the air handler which results in restricted air flow and thus more static pressure.
  • the inventors of the present invention have determined that placing a transition between the air filter and the electric air handler can greatly reduce or eliminate the static pressure that would otherwise exist without the transition.
  • the transition can provide enough distance between the air filter and the evaporator coil to maximize airflow entering the base of the air handler without a restriction.
  • the transition can be sized to the dimensions of the air handler and/or the air filter so that airflow between the air handler and the air filter can be maximized and the static pressure minimized.
  • the air filter can be sized to match the dimensions of the transition.
  • providing the transition with a removable access panel or door can allow for cleaning/inspection of the evaporator coil and/or air filter without having to disassemble the components of the HVAC system.
  • HVAC heating, ventilation and air conditioning
  • an air conditioning system comprises: an air handler; an evaporator coil in the air handler; a blower in the air handler; a heater in the air handler; an air filter; and a transition between the air handler and the air filter.
  • the air conditioning system further comprises: an air return unit on one side of the air filter.
  • the transition comprises a panel that includes an access door that opens to allow access into an interior of the transition.
  • a length of the transition is at least 8 inches so that the air filter is at least 8 inches away from the air handler.
  • the transition includes a panel comprising one or more access ports opening into the interior of the transition.
  • the air conditioning system further comprises: an ultraviolet light mounted within the transition; and a baffle on the ultraviolet light, wherein the baffle is positioned to face the air filter to protect the air filter from being degraded by ultraviolet light.
  • a transition for an air conditioning system comprises: at least four panels that together define a perimeter of the transition and an interior of the transition; a first end configured to be attached to an air handler; a second end opposite the first end; and an air filter at the second end, wherein at least one of the at least four panels includes an access door that opens to allow access into the interior of the transition.
  • a length of the transition from the first end to the second end is at least 8 inches.
  • At least one of the at least four panels includes one or more access ports opening into the interior of the transition.
  • the at least four panels are configured to be detachably attached to each other to allow the transition to be field assembled at a job site.
  • At least one of the at least four panels includes a mounting port for mounting an ultraviolet light and baffle within the interior of the transition.
  • a method of transitioning within an air conditioning system comprises: positioning a first opened end of a transition at a first opened end of an air handler comprising an evaporator coil, a blower, and a heater; and positioning a first side of an air filter at a second opened end of the transition, the second opened end being opposite the first opened end of the transition.
  • the method further comprises: positioning an opened end of an air return unit on a second side of the air filter, the second side being opposite the first side.
  • the method further comprises: providing a panel of the transition with an access door that opens to allow access into an interior of the transition.
  • the air filter is positioned at the second opened end of the transition to be at least 8 inches away from the air handler.
  • the method further comprises: providing a panel of the transition with one or more access ports opening into the interior of the transition.
  • the method further comprises: mounting an ultraviolet light within the transition, wherein a baffle is positioned on the ultraviolet light to face the air filter to protect the air filter from being degraded by ultraviolet light.
  • FIG. 1 is a front side perspective view of an example of a combined component field-assembled sheet metal heating, ventilation and air conditioning (HVAC) air conveyance apparatus, according to some embodiments;
  • HVAC heating, ventilation and air conditioning
  • FIG. 2 is an opposite, rear side perspective view of the example combined component field-assembled sheet metal HVAC air conveyance apparatus of FIG. 1 , according to some embodiments;
  • FIG. 3 is a partially exploded perspective view of a combined component field-assembled sheet metal HVAC air conveyance apparatus, according to some embodiments
  • FIG. 4 is a perspective view of an example solid end component panel for a field-assembled sheet metal HVAC air conveyance apparatus, according to some embodiments
  • FIG. 5 is a perspective view of an example doored end component panel for a field-assembled sheet metal HVAC air conveyance apparatus, according to some embodiments
  • FIG. 6 is a perspective view of an example side component panel for a field-assembled sheet metal HVAC air conveyance apparatus, according to some embodiments.
  • FIG. 7 is an enlarged perspective view of an example hemmed cleat employed in the panels of FIGS. 1 thorough 6 , according to some embodiments;
  • FIG. 8 is a further enlarged end view of an example hemmed cleat employed in the panels of FIGS. 1 thorough 6 , according to some embodiments;
  • FIG. 9 is perspective view of the example doored end component panel of FIG. 5 , one example side component panel of FIG. 6 , the example solid end component panel, of FIG. 4 and another example side component panel of FIG. 6 stacked, according to some embodiments:
  • FIG. 10 is perspective view of the example doored end component panel of FIG. 5 , two example side component panels of FIG. 6 and the example solid end component panel, of FIG. 4 and stacked, according to some embodiments;
  • FIG. 11 is flowchart of a process for field-assembly of a sheet metal HVAC air conveyance apparatus, according to some embodiments.
  • FIG. 12 is a perspective diagrammatic view of a HVAC system employing an embodiment of the present field-assembled sheet metal air conveyance apparatus, according to some embodiments.
  • FIG. 13 is a side perspective view of a heating, ventilation and air conditioning (HVAC) system including an air conveyance apparatus, according to some embodiments.
  • HVAC heating, ventilation and air conditioning
  • FIG. 14 A is an exploded perspective view of an ultraviolet light and baffle assembly that may be included in the heating, ventilation and air conditioning (HVAC) system, according to some embodiments.
  • HVAC heating, ventilation and air conditioning
  • FIG. 14 B is a perspective view of the baffle side of the assembled ultraviolet light and baffle assembly, according to some embodiments.
  • FIG. 14 C is a perspective view of the ultraviolet light side of the assembled ultraviolet light and baffle assembly, according to some embodiments.
  • FIG. 15 is a side perspective view of a heating, ventilation and air conditioning (HVAC) system including another air conveyance apparatus, according to some embodiments.
  • HVAC heating, ventilation and air conditioning
  • FIG. 16 is a diagrammatic view of a method of transitioning within an HVAC system employing an air conveyance apparatus, according to some embodiments.
  • HVAC Heating, ventilating and/or air conditioning
  • SEER Seasonal Energy Efficiency Ratio
  • Embodiments herein relate generally to HVAC systems and, more particularly, to field-assembled air conveyance apparatuses, such as field-assembled HVAC sheet metal transitions, and systems and methods related thereto.
  • a field-assembled (insulated) sheet metal to field-assembled air conveyance apparatus such as a sheet metal transition that is adapted to be install in between the outlet of a furnace (or other forced air hander) and a cased air conditioning evaporation coil, are disclosed.
  • a plurality of panels are adapted to be field-assembled to form the air conveyance apparatus.
  • These panels may include a pair of first quadrilateral panels, each defining a right-angle flange extending from each of a pair of opposite edges and a pair of second quadrilateral panels, each defining a hemmed cleat along each of a pair of opposite edges.
  • Each hemmed cleat is shaped and dimensioned to receive one of the first quadrilateral panel right-angle flanges to form the air conveyance apparatus.
  • HVAC unit mating flanges may extend from each other edge of each of the first quadrilateral panels and/or from each other edge of each of the second quadrilateral panels, such that at least a pair of opposed peripheral HVAC unit mating flanges extend from each end of the HVAC air conveyance apparatus.
  • Embodiments of the present field-assembled (insulated) sheet metal air conveyance apparatus are a knockdown multi-panel unit, which is adapted to be packaged, transported, and dispatched in a minimized footprint configuration.
  • Embodiments of the unit utilize a series of flange and hem fasteners, such that the unit can be field-assembled at the site of the application, utilizing minimal tools.
  • the panels used in accordance with the present systems and methods are sized for many configurations for various application conformity.
  • the panel walls can be secured in place using a series of fitted material bends that allow one flange to be inserted into an adjacent panel's open hem. Furthermore, a (single) securing screw can lock the panels together.
  • the unit includes a fibrous insulation, which when coupled with the application appliance, improves sound-deadening properties. R-value properties, resistance to moisture and biology, and fire safety.
  • the double open-ended air conveyance apparatus can be placed between “inappropriately” sized and “non-conforming” air systems (i.e., cased oils, furnaces or other air handlers that that have different dimensioned outlet and in inlet openings, as duct transitions, in laboratory air handling testing application configurations, or the like).
  • FIG. 1 is a front side perspective view of example combined component field-assembled sheet metal air conveyance apparatus (e.g., a transition) 100
  • FIG. 2 is an opposite, rear side perspective view of example combined component field-assembled sheet metal air conveyance apparatus 100
  • FIG. 3 is a partially exploded perspective view of combined component field-assembled sheet metal HVAC air conveyance apparatus 100 , according to some embodiments.
  • Combined component field-assembled sheet metal air conveyance apparatus 100 includes solid end component panel 102 , which in illustrated embodiment 100 forms the back (i.e., serves as the rear panel) of the combined component field-assembled sheet metal air conveyance apparatus.
  • FIG. 4 is a perspective view of example solid end component panel 102 , according to some embodiments.
  • Doored end component panel 104 forms a front of field-assembled sheet metal air conveyance apparatus 100 .
  • FIG. 5 is a perspective view of example doored end component panel 104 , according to some embodiments.
  • a combined component field-assembled sheet metal air conveyance apparatus may comprise two solid end component panels 102 , rather than one each of solid end component panel 102 and doored end component panel 104 .
  • the combined component field-assembled sheet metal air conveyance apparatus such as illustrated combined component field-assembled sheet metal air conveyance apparatus (e.g., a transition) 100 , also includes two, opposite side component panels 106 .
  • FIG. 6 is a perspective view of example side component panel 106 for field-assembled sheet metal air conveyance apparatus 100 , according to some embodiments.
  • Side component panels 106 may be symmetrical, such as illustrated in FIGS. 1 , 2 and 5 , and thereby interchangeable for field-assembly of a sheet metal air conveyance apparatus in accordance with embodiments of the present systems and methods.
  • FIG. 7 is an enlarged perspective view of example hemmed cleat 108 employed in the panels of FIGS. 1 thorough 5
  • FIG. 8 is a further enlarged end view of example hemmed 108 , according to some embodiments.
  • the hemmed cleat accepts any properly sized flange within the opening and then is able to be secured with a fastener to hold the two panels together.
  • an embodiment of HVAC air conveyance apparatus (e.g., a transition) 100 may include a plurality of each of panels 102 and 106 , but in some embodiments one of each side panel 102 and 104 and two of end panels 106 .
  • HVAC air conveyance apparatus 100 e.g., a transition
  • Each panel may be formed out of sheet metal, such as galvanized steel, aluminum, stainless steel, powder coated steel, pre-painted steel, other iron-carbon alloy combination, or the like, or may be formed out of other materials such as a plastic or other polymer.
  • air conveyance apparatus 100 may be assembled using, by way of example, only four fasteners.
  • the plurality of panels includes a pair of first quadrilateral panels, end panels 102 and 104 .
  • each first quadrilateral (end) panel 102 or defines a right-angle (i.e., generally 90 degree) flange 110 a through 110 d extending, generally inward, as illustrated in FIGS. 3 and 4 , from each of a pair of opposite edges 112 a through 112 d .
  • Each of end panels 102 and 104 may also define HVAC unit mating flanges 114 a through 114 d extending from each other edge 116 a through 116 d of each first quadrilateral (end) panel 102 and 104 , respectively. As shown in FIG.
  • At least one of the panels making up air conveyance apparatus (e.g., a transition) 100 may have an HVAC component access door 118 .
  • FIG. 5 shows end panel 104 with HVAC component access door 118 .
  • Retaining latches 120 may be used to removably secure door 118 (closed) on panel 104 .
  • door 118 may be fastened to (peripherical) door frame 122 of panel 104 by means of latches 120 .
  • Latches 120 may swivel about a concentric point (on the (insulated) door) with a predetermined rotational degree of freedom.
  • the aforementioned plurality of panels making up HVAC air conveyance apparatus (e.g., a transition) 100 also includes a pair of second quadrilateral panels, side panels 106 .
  • each second quadrilateral (side) panel 106 defines hemmed cleat 108 a or 108 b along each of a pair of opposite edges 124 a and 124 b .
  • side panels 106 may also define HVAC unit mating flanges, similar to HVAC mating flanges 114 of end panels 102 and 104 , extending from each other edge 126 a and 126 b of each second quadrilateral (side) panel.
  • Each hemmed cleat 108 is shaped and dimensioned to snuggly (e.g., within a functional snug fit tolerance) receive one of the first quadrilateral panel right-angle flanges 110 to form HVAC air conveyance apparatus 100 , with peripheral HVAC unit mating flanges 114 extending from each end of assembled HVAC air conveyance apparatus 100 , as best seen in FIGS. 1 and 2 .
  • each hemmed cleat 108 has, in accordance with various embodiments, hem butt end 128 extending generally perpendicular from face 130 of the respective second quadrilateral (side) panel 106 , and along and spaced apart from, respective edge 124 of the second quadrilateral (side) panel.
  • the integral hemmed cleat 108 further defines projecting lip 132 extending from hem butt end 128 , generally parallel to face 130 of the respective second quadrilateral (side) panel, toward respective edge 124 , and spaced apart from face 130 a distance to define hemmed cleat slot 134 .
  • Open hem thickness slot 134 is sized to snug fit receive first quadrilateral (end) panel right-angle flange 110 .
  • Each of hemmed cleats 108 may has screw receptive hole 136 defined through projecting lip 132 .
  • Screw receptive hole 136 may be pilot hole, sized to receive fastener 138 to secure first quadrilateral panel right-angle flange 110 received in hemmed cleat slot 134 in the hemmed cleat slot, to form HVAC air conveyance apparatus (e.g., a transition) 100 .
  • each first quadrilateral (end) panel right-angle flange 110 may have a smaller right-angle flange screw receptive pilot hole 140 defined through the right-angle flange.
  • This right-angle flange screw receptive pilot hole is spaced along right-angle flange 110 to align with screw receptive pilot hole 136 defined through projecting lip 132 of hemmed cleat 108 when the right-angle flange is received in hemmed cleat slot 134 defined by the projecting lip.
  • smaller right-angle flange screw receptive pilot hole 140 may be sized (smaller than hemmed cleat screw receptive pilot hole 136 ) to threadably receive fastener 138 to form HVAC air conveyance apparatus 100 .
  • fastener 138 may be a self-threading, self-tapping, self-drilling, or similar screw, or the like.
  • right-angle flange 110 may not define a screw receptive pilot hole, and in such embodiments the fastener may be a drill screw, which may be disposed through hemmed cleat screw receptive pilot hole 136 defined through projecting lip 132 and drill-screwed into right-angle flange 110 to form HVAC air conveyance apparatus 100 .
  • each panel of the plurality of panels 102 , 104 and 106 may, in accordance with embodiments of the present systems and methods, be generally quadrilateral in shape. Some panels may further be trapezoidal in shape. For example, each edge 124 of the pair of opposite edges of each second quadrilateral (side) panel are illustrated as trapezoidal legs for the respective panel. Also, correspondingly, each of other edge 126 of each second quadrilateral side panel are illustrated as trapezoidal bases for each respective panel. In various embodiments each such trapezoidal panel may generally have an isosceles trapezoidal shape. That is, where base angles have the same measure, the two legs, edge pairs 124 a and 124 b are of equal length and each respective panel has reflection symmetry. In some embodiments some or all of the panels may be rectangular (or square) in shape.
  • (rigid) insulation (panels) 142 such as certified insulation panels, or the like, may be disposed (e.g., secured, glued, compression fit, pinched, wedged via application of flange after having inserted the insulation, cupped head (weld) pinned, and/or the like) on an inner surface of each panel 102 , 104 and 106 of the plurality of panels forming HVAC air conveyance apparatus (e.g., a transition) 100 , including, in some embodiments (not shown) on an inner surface of door 118 .
  • the insulation panels may have a pressure sensitive adhesive applied foil laminate surface, or other reflective layer such as foil with radiation insulation properties.
  • air purification coating 144 may be disposed on an inner surface of insulation panels 142 and thus on an inner surface of the HVAC air conveyance apparatus 100 in contact with airflow through the installed air conveyance apparatus.
  • an air purification coating may be disposed directly on the inner surface of each panel 102 , 104 and 106 , of the plurality of panels forming the HVAC air conveyance apparatus, including on an inner surface of door 118 , in contact with airflow through the installed air conveyance apparatus.
  • Manganese dioxide such as in combination with Titanium dioxide, may be used to coat interior surfaces of air conveyance apparatus 100 .
  • Manganese dioxide exhibits thermocatalytic activity for the decomposition of organic pollutants. Coupling Titanium dioxide with Manganese dioxide degrades organics further than Titanium dioxide alone, due to the thermocatalytic activity of Manganese dioxide.
  • one or more of the panels e.g., side panels 106
  • These prefabricated (pilot) holes may be accompanied by a “call out” that can be a sticker (over the prefabricated (pilot) holes), metal engraving, laminate, painted, etc. (not shown).
  • At least one of the panels making up air conveyance apparatus may have an HVAC component access door 118 .
  • Figure S shows end panel 104 with HVAC component access door 118 .
  • Retaining latches 120 in FIG. 5 removably secure door 118 (closed) to panel door frame 122 of panel 104 .
  • door 118 may be fastened to (peripherical) door frame 122 of panel 104 by means of latches 120 , such as by each of latches 120 swiveling about a concentric point 146 , on (insulated) door 118 ) a predetermined amount, such as generally about ninety degrees.
  • Door frame 122 may define door frame slots 148 for receiving the jaw section 150 of latches 120 .
  • This door latching mechanism may provide “stay-locked” features to combat pressure variances that may otherwise cause door 118 to (unlatch and) open, unlike prior latches where there is minimal resiliency to forces that may cause the door latch to rotate to an open position when a load is applied to the door, thus triggering the door to leak or freely open during operation.
  • torque is applied from door frame 122 to latch (arm) 120 that causes it to rotate further into the “locking” direction (i.e., toward inside frame ledge 152 ).
  • the edge of the slot ( 148 ) in door frame 122 imposes a force onto the arm portion of latch 150 .
  • This tangential force acting on the latch arm ( 150 ) is a predetermined distance away from fastener 146 , thereby acting as a moment arm.
  • the resulting torque thereby applied to latch 120 causes the latch to be rotationally forced into its locking, or securing, position inside of slot 148 .
  • This torque can be overcome by a human operator applying an opposing torque on the latch by means of the latch tab, thereby causing the latch to rotate into an “un-locked” position before servicing.
  • Door 118 , and frame 122 may be sized such that removal of door 118 , by release of laches 120 , may, may remove (almost) an entire face of assembled air conveyance apparatus 100 .
  • Door 118 is fit to bottom out on inside ledge 152 of door frame 122 so as to seal against leakage of air.
  • the combined, or complementary, geometry of door 188 , frame 122 and/or frame ledge 152 may enable compression of insulation 142 , such that the insulation acts as a gasket, or enable a flush sheet metal on sheet metal edge between door edge 154 and inside frame ledge 152 .
  • panels 102 , 104 and 106 may be prepared for shipment into the field and eventual assembling into air conveyance apparatus (e.g., a transition) 100 by (alternately) stacking the pair of first, quadrilateral (end) panels 102 and 104 with the pair of second quadrilateral (side) panels 106 , in various configurations.
  • air conveyance apparatus e.g., a transition
  • embodiments of the present field-assembled sheet metal air conveyance apparatus save on shipping costs, particularly as compared to one piece, or fully assembled air conveyance apparatus.
  • FIG. 9 is perspective view of example doored end component panel 104 of FIG. 5 , one example side component panel 106 of FIG. 6 , example solid end component panel 104 of FIG.
  • panels 102 , 104 and 106 may be prepared for shipment into the field and eventual assembling into air conveyance apparatus 10 ) by stacking the panels with doored end panel 104 and solid (back) end panel 102 are on the outside of the stack with the (two) side panels 106 disposed between, such as illustrated in FIG. 10 .
  • FIG. 11 is flowchart of process 1100 for field-assembly of a sheet metal air conveyance apparatus ( 100 ) (and its use in an HVAC system ( 1000 )), according to some embodiments.
  • the panels ( 102 , 104 and 106 ) to be used in the air conveyance apparatus e.g., a transition
  • the air conveyance apparatus e.g., a transition
  • the panels ( 102 , 104 and 106 ) to be used in the air conveyance apparatus are unstacked and at 1105 a pair of first (end) quadrilateral panels ( 102 and 104 ) are assembled to a pair of second (side) quadrilateral panels ( 106 ) to form a HVAC air conveyance apparatus ( 100 ).
  • Assembly at 1105 is carried out by, at 1110 , inserting a right-angle flange ( 110 ) extending (inward) from each of a pair of opposite edges ( 112 ) of each of the first (end)quadrilateral panels ( 102 or 104 ) into a hemmed cleat ( 108 ) defined along each of a pair of opposite edges ( 124 ) of each of a respective one of the second (side) quadrilateral panels; 106 .
  • each of the first quadrilateral (end) panels ( 102 and 104 ) is secured to the respective one of the second quadrilateral (side) panels ( 106 ) with a fastener ( 138 ) received through a pilot hole ( 136 ) defined through a projecting lip ( 132 ) of the hemmed cleat ( 108 ) of each of the second quadrilateral (end) panels into the right-angle flange ( 110 ) extending from the respective one of the first quadrilateral (side) panels.
  • Securing the panels at 1115 may include, by way of example receiving the fastener ( 138 ) through the fastener receptive pilot hole ( 136 ) defined through the projecting lip ( 132 ) of the hemmed cleat ( 108 ) of each of the second quadrilateral (side) panels ( 106 ) into a screw receptive pilot hole ( 140 ) defined in the right-angle flange ( 110 ) extending from the respective one of the first second quadrilateral (end) panels ( 102 or 104 ).
  • FIG. 12 is a perspective diagrammatic view of HVAC system 1200 employing an embodiment of the present field-assembled sheet metal air conveyance apparatus (e.g., a transition) 100 , according to some embodiments.
  • HVAC system 1200 includes first HVAC unit 1205 , which may be an air handling unit, such as a gas or electric furnace, or the like, and second HVAC unit 1210 , which may be a set of cased air conditioning evaporator coils, or the like.
  • An embodiment of the present field-assembled sheet metal HVAC air conveyance apparatus 100 is disposed between, and secured to, first HVAC unit 1205 and second HVAC unit 1210 .
  • first HVAC unit 1205 may be a set of cased air conditioning evaporator coils, or the like
  • second HVAC unit 1210 may be an air handling unit, such as a gas or electric furnace, or the like.
  • An embodiment of the present field-assembled sheet metal HVAC air conveyance apparatus 100 is disposed between, and secured to, first HVAC unit 1205 and second HVAC unit 1210 .
  • first unit 1205 and second unit 1210 may be units to be tested in operation together and air conveyance apparatus 100 may act as an air conveyance apparatus between units 1205 and 1210 .
  • first unit 1205 and second unit 1210 may be testing units, research units, or the like, joined by air conveyance apparatus 100 to act as an air conveyance apparatus between units 1205 and 1210 .
  • the assembled HVAC air conveyance apparatus ( 100 ) is disposed, at 1120 , between a first HVAC unit ( 1205 ) and a second HVAC unit ( 1210 ), with HVAC unit mating flanges 114 extending from each other opposite edge 116 of each first and/or second quadrilateral panels ( 102 and 104 , or 106 ) received securable by an open end of each of the first and second HVAC units ( 1205 and 1210 ).
  • the assembled HVAC air conveyance apparatus ( 100 ) is secured between the first HVAC unit ( 1205 ) and the second HVAC unit ( 1210 ) using a plurality of fasteners ( 1215 ) through (a side of the respective HVAC unit and) the HVAC unit mating flanges ( 114 ).
  • the installer may also employ tape with the intentions of sealing and further adhering the air conveyance apparatus ( 100 ) in place to the adjacent/connected HVAC appliance ( 1205 and/or 1210 ).
  • the installer, operator, or customer may also adhere tape within the inside of the unit(s) ( 1205 and/or 1210 ) and/or the air conveyance apparatus ( 100 ), in order to further seal the air conveyance apparatus in-line with connected HVAC components ( 1205 and/or 1210 ).
  • the combined components of the unit combine and yield benefits such as improved system efficiency, in that, the assembled system maintains SEER, air flow distribution, heating element exposure, and the like. Further, the combined component unit yield minimized system resistance to the system(s), such as minimized turbulence, minimized minor dynamic pressure loss, minimized flow resistance. Improved service accessibility to the system(s) is also provided in the combined component unit, including a large removable panel (door 118 ). The combined component unit further yields attenuated sound power of system(s) during operation, so as to provide an increased Sound Transmission Class (STC), increased Noise Reduction Coefficient (NRC), and/or the like. The combined component unit also yields improved resistance to fungi and/or bacteria growth between systems.
  • STC Sound Transmission Class
  • NRC Noise Reduction Coefficient
  • the combined component unit has low moisture absorption, and thus, eliminates harboring of potential biological life. Improved passive fire protection of system(s) and the associated structure, in the combined component unit is non-combustible.
  • the combined component unit further provides reduced (risk of) chemical exposure and deposition throughout the system(s) and structure, in that certified insulation, or the like, used in the combined component unit is proven to reduce indoor air pollution, and the like.
  • Leak testing was conducted on an embodiment of the present air conveyance apparatus.
  • the apparatus was assembled on site, as is intended to be done by an installer or operator at the scene of installation, and then subjected to internal flow by fans that replicate typical HVAC flow parameters.
  • volumetric flow rates were captured by testing facility provided vent hoods in such a way that recorded air successfully channeled through the apparatus, as well as air that escaped through the confines of the apparatus. Under steady state volumetric flow of 1600 cubic feet per minute, both volumetric flow rates of channeled air and leaked air were recorded simultaneously.
  • FIG. 13 illustrates a side perspective view of a heating, ventilation and air conditioning (HVAC) system 200 including an air conveyance apparatus (e.g., a transition) 100 that obviates the increase in static pressure caused by conventional air filter placement.
  • HVAC heating, ventilation and air conditioning
  • the air conveyance apparatus e.g., a transition 100
  • the air conveyance apparatus may be formed of the panels 102 , 104 , 106 discussed above, and may include any or all of the associated features discussed above with respect to FIGS. 1 to 10 .
  • the air conveyance apparatus (e.g., transition) 100 may be a pre-fabricated transition with panels that are assembled at a factory (e.g., non-knockdown transition), such that the air conveyance apparatus (e.g., transition) 100 is installed whole in the field.
  • the air conveyance apparatus (e.g., transition) 100 may be formed of at least four panels (e.g., 102 , 104 , 106 ) that together define a perimeter of the air conveyance apparatus (e.g., transition) 100 and an interior thereof.
  • the air conveyance apparatus (e.g., transition) 100 may have a first end configured to be attached to an electric air handler 202 as shown in FIG. 13 , and a second end opposite the first end.
  • the air conveyance apparatus (e.g., transition) 100 may be attached to the electric air handler 202 via clips, snaps, screws, tape, adhesive, or other attaching devices.
  • the HVAC system 200 includes an electric air handler 202 .
  • An evaporator coil (or a set of evaporator coils) 204 , an air blower 206 , and a heater (or furnace) 208 may be provided inside the electric air handler 202 .
  • the evaporator coil (or set of evaporator coils) 204 may be any type of coil, and may include, for example, box coils or slab coils, either of which may be in an arrangement that is horizontal, vertical, or a combination thereof.
  • Example box coils include multi-poise A-coils, performance A-coils, and N-coils.
  • the blower 206 may include a motor that forces heated or cooled air passing over the evaporator coil 204 through the ducts (not shown) of the HVAC system 200 , and out of vents in rooms throughout the house or building having the HVAC system 200 .
  • the heater (or furnace) 208 of the HVAC system 200 may include components, such as an electric heating element, that heat air passing through the electric air handler 202 and circulating through the HVAC system 200 .
  • the HVAC system 200 also includes an air filter 210 that may remove impurities such as dust, pet dander and/or bacteria from the air flowing through the HVAC system 200 .
  • an air conveyance apparatus e.g., a transition
  • placing an air conveyance apparatus 100 between the air filter 210 and the electric air handler 202 can greatly reduce or eliminate the static pressure that would otherwise exist without a transition.
  • the air conveyance apparatus (e.g., a transition) 100 can provide enough distance between the air filter 210 and the evaporator coil 204 inside the electric air handler 202 to maximize airflow entering the base of the electric air handler 202 without a restriction, in some embodiments, the length of the air conveyance apparatus (e.g., a transition) 100 from a first end thereof that abuts the electric air handler 202 to an opposite second end that abuts the air filter 210 may be at least 8 inches, so that when the air conveyance apparatus (e.g., a transition) 100 is provided between the air filter 210 and the electric air handler 202 the air filter 210 is at least 8 inches away from the electric air handler 202 and the evaporator coil 204 inside the electric air handler 202 .
  • This length of the air conveyance apparatus (e.g., a transition) 100 (or distance between the electric air handler 202 and the air filter 210 ) may allow the air blower 206 to operate without any overworking.
  • the length of the air conveyance apparatus (e.g., a transition) 100 from a first end thereof to the opposite second end may be 8 inches to 9 inches in order provide better air flow from the air filter 210 on the second opposite end of the air conveyance apparatus (e.g., a transition) 100 to the electric air handler 202 on the first end.
  • the length of the of the air conveyance apparatus (e.g., a transition) 100 from a first end thereof to the opposite second end may be greater than 9 inches depending on the design and requirements of the HVAC system 200 .
  • the air conveyance apparatus (e.g., a transition) 100 can be sized to the dimensions of the electric air handler 202 and/or the air filter 210 so that airflow between the air handler 202 and the air filter 210 can be maximized and the static pressure minimized.
  • the air filter 210 can be sized to match the dimensions of the air conveyance apparatus (e.g., a transition) 100 .
  • FIG. 13 shows an embodiment in which the first end of the air conveyance apparatus (e.g., a transition) 100 has a perimeter that is smaller than the perimeter of the second opposite end thereof, so that the perimeter of first end is sized to match the dimension of the smaller opening of the electric air handler 202 .
  • the larger perimeter of the second opposite end of the air conveyance apparatus (e.g., a transition) 100 matches the dimension of the larger perimeter of the air filter 210 . Sizing these components to match or fit the dimensions of each other as described in the example above can eliminate the offset between the air filter 210 and the electric air handier 202 , which would otherwise result in restricted air flow and thus increased static pressure.
  • the air conveyance apparatus (e.g., a transition) 100 may include the air filter 210 , such that the air filter 210 is a part of the air conveyance apparatus (e.g., a transition) 100 .
  • the air filter 210 may be a replaceable part of the air conveyance apparatus (e.g., a transition) 100 .
  • the air filter 210 may be attached to the air conveyance apparatus (e.g., transition) 100 via clips, snaps, screws, tape, adhesive, or other attaching devices.
  • FIG. 13 shows that the HVAC system 200 may also include an air return unit 212 on a side of the air filter 210 that is opposite the side that abuts the air conveyance apparatus (e.g., a transition) 100 .
  • the air return unit 212 may allow the air in the house or building having the HVAC system 200 to return to the system for continued heating or cooling.
  • one of the panels 104 of the air conveyance apparatus (e.g., a transition) 100 may include the removable access door 118 discussed herein.
  • the removable access door 118 may allow for access into the interior of the air conveyance apparatus (e.g., a transition) 100 for cleaning and/or inspection of the evaporator coil 204 and/or the air filter 210 without having to disassemble the component parts of the HVAC system 200 .
  • instruments that measure static pressure can be inserted into the air conveyance apparatus (e.g., a transition) 100 through the opening in the panel 104 provided by the removable access door 118 .
  • one or more of the panels 102 , 106 of the air conveyance apparatus (e.g., a transition) 100 may include one or more access ports 214 opening into the interior of the air conveyance apparatus (e.g., a transition) 100 .
  • the access ports 214 may be pre-punched holes of any kind.
  • the access ports 214 may permit access for a variety of reasons, e.g., for installing and/or mounting of: static pressure measuring devices; air flow and air quality metering devices; and temperature and other types of probes or metering devices for testing temperature and other metrics within the HVAC system 200 .
  • the mounting may be accomplished, for example, by any fastening devices known or available.
  • one or more of the panels 102 , 106 of the air conveyance apparatus (e.g., a transition) 100 may include a mounting port 216 opening into the interior of the air conveyance apparatus (e.g., a transition) 100 .
  • the mounting port 216 may be a pre-punched hole of any kind, and may permit access for and mounting of an ultraviolet light and baffle assembly 218 within the interior of the air conveyance apparatus (e.g., a transition) 100 .
  • the mounting may be accomplished, for example, by any fastening devices known or available.
  • FIG. 14 A illustrates the main components of the ultraviolet light and baffle assembly 218 according to an embodiment.
  • the ultraviolet light and baffle assembly 218 includes an ultraviolet light emitter 219 or other ultraviolet radiant tube device, and a baffle 220 that is configured to be detachably attached to the ultraviolet light emitter 219 .
  • the baffle 220 may be detachably attached to the ultraviolet light emitter 219 via. e.g., clips 221 that grip ends or other portions of the ultraviolet light emitter 219 .
  • FIG. 14 B is a perspective view of the baffle side of the assembled ultraviolet light and baffle assembly 218 .
  • the baffle side is adapted to face the filter 210 when mounted within the air conveyance apparatus (e.g., a transition) 100 to protect the air filter 210 from being degraded by the ultraviolet light from the ultraviolet light emitter 219 .
  • the ultraviolet light from the ultraviolet light emitter 219 may eliminate mold and mildew, kill viruses and bacteria, and reduce odors, thus increasing the efficiency of the HVAC system 200 and improving the quality of the indoor air in the HVAC system 200 .
  • FIG. 14 C is a perspective view of the ultraviolet light side of the assembled ultraviolet light and baffle assembly 218 .
  • the ultraviolet light side is adapted to face the evaporator coil(s) 204 of the electric air handler 202 when mounted within the air conveyance apparatus (e.g., a transition) 100 to help clean the evaporator coil(s) 204 and air that passes through the HVAC system naturally.
  • the air conveyance apparatus e.g., a transition
  • FIG. 15 illustrates another embodiment of the HVAC system 200 in which the removable access door 118 on a top panel of the air conveyance apparatus (e.g., a transition) 100 .
  • Other components of the HVAC system 200 shown in FIG. 15 may be the same or similar as in the system shown and described herein with respect to FIG. 13 .
  • FIG. 16 is a diagrammatic view of a method 300 of transitioning within an HVAC system 200 employing an air conveyance apparatus (e.g., a transition) 100 according to some embodiments.
  • the method 300 may begin after the field assembly process 1100 shown in FIG. 11 and described above has been completed.
  • a first opened end of the assembled air conveyance apparatus (e.g., a transition) 100 is positioned at a first opened end of the electric air handler 202 , which air handler includes the evaporator coil(s) 204 , the air blower 206 , and the heater (or furnace) 208 as discussed above.
  • a first side of the air filter 210 discussed herein is positioned at a second opened end of the air conveyance apparatus (e.g., a transition) 100 , the second opened end being opposite the first opened end of the air conveyance apparatus (e.g., a transition) 100 .
  • the air filter 210 may be positioned at the second opened end of the air conveyance apparatus (e.g., a transition) 100 to be at least 8 inches away from the air handler 202 as discussed herein.
  • one of the panels 104 of the air conveyance apparatus (e.g., a transition) 100 may be provided with the removable access door 118 that opens to allow access into the interior of the air conveyance apparatus (e.g., a transition) 100 .
  • one of the panels 102 , 206 of the air conveyance apparatus (e.g., a transition) 100 may be provided with one or more access ports 214 opening into the interior of air conveyance apparatus (e.g., a transition) 100 .
  • an opened end of the air return unit 212 may be positioned on a second side of the air filter 210 , the second side being opposite the first side of the air filter 210 .
  • an ultraviolet light and baffle assembly 218 may be mounted within the air conveyance apparatus (e.g., a transition) 100 .
  • a baffle 220 may be positioned on the ultraviolet light 219 to face the air filter 210 to protect the air filter 210 from being degraded by ultraviolet light.

Abstract

An air conditioning system includes an air handler, an evaporator coil, a blower and a heater all within the air handler. The system further includes an air filter and a transition between the air handler and the air filter. The transition includes at least four panels that together define a perimeter and an interior of the transition. A first end of the transition is configured to be attached to the air handler. A second end of the transition is opposite the first end, and an air filter is disposed at the second end. At least one of the at least four panels includes an access door that opens to allow access into the interior of the transition. A method includes positioning the first end of the transition at a first end of the air handler, and positioning the air filter at the second end of the transition.

Description

    CROSS REFERENCE TO RELATED APPLICATIONS
  • The present application is a continuation-in-part of U.S. patent application Ser. No. 17/643,226 filed on Dec. 8, 2021, having a title of “Field-Assembled Air Conveyance Apparatus, Systems and Methods”. The contents of the prior application are hereby incorporated by reference herein in their entirety.
  • TECHNICAL FIELD
  • The present disclosure relates generally to heating, ventilating and/or air conditioning (HVAC) systems and, more particularly, to field-assembled air conveyance apparatuses, such as field-assembled HVAC sheet metal transitions, and systems and methods utilizing air conveyance apparatuses.
  • BACKGROUND
  • When installing a cased air conditioning evaporator coil on the top, or other outlet, of a high Seasonal Energy Efficiency Ratio (SEER) furnace the inlet dimensions of the coil, may not be the same dimensions as the outlet of the furnace. In most cases the outlet of the furnace is smaller than the inlet of the coil and a reduction in air flow is created such that SEER ratings are not achieved. Furthermore, prescribed servicing of aforementioned appliances are restricted and in some cases not achievable, thus requiring a full disassembly/separation of the appliances to gain access to needed internal components.
  • Transitions, or the like, used to join an air handling unit, such as a furnace, and another unit, such as the aforementioned air conditioning evaporator coil, are formed from sheet metal in an off-site shop and transported to a job site. Shipping or other transport of such an open-ended transition, or the like, is problematic in that it is bulky and structurally unsound, alone. For example, it is often necessary to mount the transition on a palette which greatly increases shipping or transportation costs.
  • One of the more important factors that affect efficiency of an HVAC system is static pressure. Static pressure can be defined as the resistance to airflow within the ductwork in an HVAC system and in an electric air-handler or heat-pump and other components. For an HVAC system to operate efficiently, air must be pushed through the air ducts with greater intensity than the static pressure level within the system. If the HVAC system does not meet this condition, airflow can be adversely restricted. Thus, the lower the static pressure, the better the efficiency.
  • SUMMARY
  • In general, a static pressure of 0.5 inches per water column (in. W.C.) or lower is ideal. A static pressure greater than 0.5 in. W.C. can result in several problems. For example, the restricted airflow caused by a larger static pressure can result in noisy heating and cooling equipment. The higher the static pressure, the louder the noise in the HVAC system will be. In addition, impaired airflow can result in undesirable hot spots, cold spots, or air that hovers above a register. This is because when static pressure is high, the HVAC system tends to move too much air, or an insufficient amount of, air per ton. Moreover, the inefficiency caused by high static pressures can place undue strain on the compressor, the blower motor, and/or other components of the HVAC system, because the system must work harder to compensate for poor airflow. The undue strain can lead to premature equipment failure and hence expensive repairs. Of course, inefficiency can also increase the amount of energy needed to run the HVAC system, resulting in higher electricity bills. Finally, high static pressures may also adversely affect the refrigerant when charging the unit, and may cause air filters to load up with particulates faster than normal.
  • HVAC systems may use one or more air filters to remove impurities such as dust, pet dander or even bacteria from the air flowing through the system. Conventionally, an air filter has been positioned in an HVAC system at a location abutting the base of the electric air handling unit. In that location, the air filter is close to or adjacent the evaporator coil in the air handling unit. This position of the air filter relative to the evaporator coil increases the static pressure in the HVAC system. This is especially true when the dimensions of the air filter are greater than the dimensions of the inlet of the air handler, e.g., when the perimeter of the filter is greater than the perimeter of the inlet. The differences in size create an offset between the air filter and the air handler which results in restricted air flow and thus more static pressure.
  • The inventors of the present invention have determined that placing a transition between the air filter and the electric air handler can greatly reduce or eliminate the static pressure that would otherwise exist without the transition. The transition can provide enough distance between the air filter and the evaporator coil to maximize airflow entering the base of the air handler without a restriction. Further, the transition can be sized to the dimensions of the air handler and/or the air filter so that airflow between the air handler and the air filter can be maximized and the static pressure minimized. Conversely, the air filter can be sized to match the dimensions of the transition. In addition, providing the transition with a removable access panel or door can allow for cleaning/inspection of the evaporator coil and/or air filter without having to disassemble the components of the HVAC system.
  • The present invention is directed to systems and methods which provide a heating, ventilation and air conditioning (HVAC) air conveyance apparatus that can reduce or eliminate static pressure in an HVAC system while providing easy access for cleaning and/or inspection of the evaporator coil and/or air filter without having to disassemble the components of the HVAC system.
  • In accordance with some aspects, an air conditioning system comprises: an air handler; an evaporator coil in the air handler; a blower in the air handler; a heater in the air handler; an air filter; and a transition between the air handler and the air filter.
  • In accordance with some aspects, the air conditioning system further comprises: an air return unit on one side of the air filter.
  • In accordance with some aspects, the transition comprises a panel that includes an access door that opens to allow access into an interior of the transition.
  • In accordance with some aspects, a length of the transition is at least 8 inches so that the air filter is at least 8 inches away from the air handler.
  • In accordance with some aspects, the transition includes a panel comprising one or more access ports opening into the interior of the transition.
  • In accordance with some aspects, the air conditioning system further comprises: an ultraviolet light mounted within the transition; and a baffle on the ultraviolet light, wherein the baffle is positioned to face the air filter to protect the air filter from being degraded by ultraviolet light.
  • In accordance with further aspects, a transition for an air conditioning system comprises: at least four panels that together define a perimeter of the transition and an interior of the transition; a first end configured to be attached to an air handler; a second end opposite the first end; and an air filter at the second end, wherein at least one of the at least four panels includes an access door that opens to allow access into the interior of the transition.
  • In accordance with some further aspects, a length of the transition from the first end to the second end is at least 8 inches.
  • In accordance with some further aspects, at least one of the at least four panels includes one or more access ports opening into the interior of the transition.
  • In accordance with some further aspects, the at least four panels are configured to be detachably attached to each other to allow the transition to be field assembled at a job site.
  • In accordance with some further aspects, at least one of the at least four panels includes a mounting port for mounting an ultraviolet light and baffle within the interior of the transition.
  • Also, in accordance with some aspects, a method of transitioning within an air conditioning system comprises: positioning a first opened end of a transition at a first opened end of an air handler comprising an evaporator coil, a blower, and a heater; and positioning a first side of an air filter at a second opened end of the transition, the second opened end being opposite the first opened end of the transition.
  • In accordance with some aspects, the method further comprises: positioning an opened end of an air return unit on a second side of the air filter, the second side being opposite the first side.
  • In accordance with some aspects, the method further comprises: providing a panel of the transition with an access door that opens to allow access into an interior of the transition.
  • In accordance with some aspects, the air filter is positioned at the second opened end of the transition to be at least 8 inches away from the air handler.
  • In accordance with some aspects, the method further comprises: providing a panel of the transition with one or more access ports opening into the interior of the transition.
  • In accordance with some aspects, the method further comprises: mounting an ultraviolet light within the transition, wherein a baffle is positioned on the ultraviolet light to face the air filter to protect the air filter from being degraded by ultraviolet light.
  • This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
  • The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized that such equivalent constructions do not depart from the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
  • FIG. 1 is a front side perspective view of an example of a combined component field-assembled sheet metal heating, ventilation and air conditioning (HVAC) air conveyance apparatus, according to some embodiments;
  • FIG. 2 is an opposite, rear side perspective view of the example combined component field-assembled sheet metal HVAC air conveyance apparatus of FIG. 1 , according to some embodiments;
  • FIG. 3 is a partially exploded perspective view of a combined component field-assembled sheet metal HVAC air conveyance apparatus, according to some embodiments;
  • FIG. 4 is a perspective view of an example solid end component panel for a field-assembled sheet metal HVAC air conveyance apparatus, according to some embodiments;
  • FIG. 5 is a perspective view of an example doored end component panel for a field-assembled sheet metal HVAC air conveyance apparatus, according to some embodiments;
  • FIG. 6 is a perspective view of an example side component panel for a field-assembled sheet metal HVAC air conveyance apparatus, according to some embodiments;
  • FIG. 7 is an enlarged perspective view of an example hemmed cleat employed in the panels of FIGS. 1 thorough 6, according to some embodiments;
  • FIG. 8 is a further enlarged end view of an example hemmed cleat employed in the panels of FIGS. 1 thorough 6, according to some embodiments;
  • FIG. 9 is perspective view of the example doored end component panel of FIG. 5 , one example side component panel of FIG. 6 , the example solid end component panel, of FIG. 4 and another example side component panel of FIG. 6 stacked, according to some embodiments:
  • FIG. 10 is perspective view of the example doored end component panel of FIG. 5 , two example side component panels of FIG. 6 and the example solid end component panel, of FIG. 4 and stacked, according to some embodiments;
  • FIG. 11 is flowchart of a process for field-assembly of a sheet metal HVAC air conveyance apparatus, according to some embodiments; and
  • FIG. 12 is a perspective diagrammatic view of a HVAC system employing an embodiment of the present field-assembled sheet metal air conveyance apparatus, according to some embodiments.
  • FIG. 13 is a side perspective view of a heating, ventilation and air conditioning (HVAC) system including an air conveyance apparatus, according to some embodiments.
  • FIG. 14A is an exploded perspective view of an ultraviolet light and baffle assembly that may be included in the heating, ventilation and air conditioning (HVAC) system, according to some embodiments.
  • FIG. 14B is a perspective view of the baffle side of the assembled ultraviolet light and baffle assembly, according to some embodiments.
  • FIG. 14C is a perspective view of the ultraviolet light side of the assembled ultraviolet light and baffle assembly, according to some embodiments.
  • FIG. 15 is a side perspective view of a heating, ventilation and air conditioning (HVAC) system including another air conveyance apparatus, according to some embodiments.
  • FIG. 16 is a diagrammatic view of a method of transitioning within an HVAC system employing an air conveyance apparatus, according to some embodiments.
  • While this specification provides several embodiments and illustrative drawings, a person of ordinary skill in the art will recognize that the present specification is not limited only to the embodiments or drawings described. It should be understood that the drawings and detailed description are not intended to limit the specification to the particular form disclosed, but, on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the claims. Also, any headings used herein are for organizational purposes only and are not intended to limit the scope of the description. As used herein, the word “may” is meant to convey a permissive sense (i.e., meaning “having the potential to”), rather than a mandatory sense (i.e., meaning “must”). Similarly, the words “include,” “including,” and “includes” mean “including, but not limited to.”
  • DETAILED DESCRIPTION
  • The invention now will be described more fully hereinafter with reference to the accompanying drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. One skilled in the art may be able to use the various embodiments of the invention.
  • As noted, one of the challenges that heating, ventilating and/or air conditioning (HVAC) contractors are faced with when installing a cased coil on the top, or at the outlet, of a high Seasonal Energy Efficiency Ratio (SEER) furnace is that the inlet dimensions of the coil, are not the same dimensions as the outlet of the furnace. Similar problems arise when the inlet of the furnace is installed at the outlet of the coil. Either such installation may use a transition, or the like disposed between the units. In most cases the outlet of the furnace is smaller than the inlet of the coil and a reduction in air flow is created such that SEER ratings are not achieved or compromised, and thus, total system efficiency is hampered, distribution of thermal dynamic properties are compromised and designed or intended heat transfer and flow distributions characteristics are compromised. Transitions may also be used in laboratories, to connect testing ductwork or instrumentation to various types of air handlers, heating units, cooling units, or the like.
  • Embodiments herein relate generally to HVAC systems and, more particularly, to field-assembled air conveyance apparatuses, such as field-assembled HVAC sheet metal transitions, and systems and methods related thereto. Herein, embodiments of a field-assembled (insulated) sheet metal to field-assembled air conveyance apparatus, such as a sheet metal transition that is adapted to be install in between the outlet of a furnace (or other forced air hander) and a cased air conditioning evaporation coil, are disclosed.
  • In accordance with embodiments of the present field-assembled (insulated) sheet metal air conveyance apparatus systems and methods, a plurality of panels are adapted to be field-assembled to form the air conveyance apparatus. These panels may include a pair of first quadrilateral panels, each defining a right-angle flange extending from each of a pair of opposite edges and a pair of second quadrilateral panels, each defining a hemmed cleat along each of a pair of opposite edges. Each hemmed cleat is shaped and dimensioned to receive one of the first quadrilateral panel right-angle flanges to form the air conveyance apparatus. Also, HVAC unit mating flanges may extend from each other edge of each of the first quadrilateral panels and/or from each other edge of each of the second quadrilateral panels, such that at least a pair of opposed peripheral HVAC unit mating flanges extend from each end of the HVAC air conveyance apparatus.
  • Embodiments of the present field-assembled (insulated) sheet metal air conveyance apparatus are a knockdown multi-panel unit, which is adapted to be packaged, transported, and dispatched in a minimized footprint configuration. Embodiments of the unit utilize a series of flange and hem fasteners, such that the unit can be field-assembled at the site of the application, utilizing minimal tools. The panels used in accordance with the present systems and methods are sized for many configurations for various application conformity.
  • The panel walls can be secured in place using a series of fitted material bends that allow one flange to be inserted into an adjacent panel's open hem. Furthermore, a (single) securing screw can lock the panels together. In various embodiments, the unit includes a fibrous insulation, which when coupled with the application appliance, improves sound-deadening properties. R-value properties, resistance to moisture and biology, and fire safety. After assembly, the double open-ended air conveyance apparatus can be placed between “inappropriately” sized and “non-conforming” air systems (i.e., cased oils, furnaces or other air handlers that that have different dimensioned outlet and in inlet openings, as duct transitions, in laboratory air handling testing application configurations, or the like).
  • FIG. 1 is a front side perspective view of example combined component field-assembled sheet metal air conveyance apparatus (e.g., a transition) 100, and FIG. 2 is an opposite, rear side perspective view of example combined component field-assembled sheet metal air conveyance apparatus 100, according to some embodiments. FIG. 3 is a partially exploded perspective view of combined component field-assembled sheet metal HVAC air conveyance apparatus 100, according to some embodiments. Combined component field-assembled sheet metal air conveyance apparatus 100 includes solid end component panel 102, which in illustrated embodiment 100 forms the back (i.e., serves as the rear panel) of the combined component field-assembled sheet metal air conveyance apparatus. FIG. 4 is a perspective view of example solid end component panel 102, according to some embodiments. Doored end component panel 104 forms a front of field-assembled sheet metal air conveyance apparatus 100. FIG. 5 is a perspective view of example doored end component panel 104, according to some embodiments. In other embodiments, a combined component field-assembled sheet metal air conveyance apparatus may comprise two solid end component panels 102, rather than one each of solid end component panel 102 and doored end component panel 104.
  • Regardless, the combined component field-assembled sheet metal air conveyance apparatus, such as illustrated combined component field-assembled sheet metal air conveyance apparatus (e.g., a transition) 100, also includes two, opposite side component panels 106. FIG. 6 is a perspective view of example side component panel 106 for field-assembled sheet metal air conveyance apparatus 100, according to some embodiments. Side component panels 106 may be symmetrical, such as illustrated in FIGS. 1, 2 and 5 , and thereby interchangeable for field-assembly of a sheet metal air conveyance apparatus in accordance with embodiments of the present systems and methods. However, in other embodiments under the present systems and methods, side component panels may not be symmetrical, for example side panels that are asymmetrical may be “dimensionally reflective” such that corresponding edges are aligned. As discussed in greater detail below, embodiments of the present field-assembled sheet metal air conveyance apparatus may make use of hemmed cleats 108. FIG. 7 is an enlarged perspective view of example hemmed cleat 108 employed in the panels of FIGS. 1 thorough 5, and FIG. 8 is a further enlarged end view of example hemmed 108, according to some embodiments. The hemmed cleat accepts any properly sized flange within the opening and then is able to be secured with a fastener to hold the two panels together.
  • Thus, with attention directed to FIGS. 1 through 7 , an embodiment of HVAC air conveyance apparatus (e.g., a transition) 100 may include a plurality of each of panels 102 and 106, but in some embodiments one of each side panel 102 and 104 and two of end panels 106.
  • Regardless, panels 102, 104 and 106 are adapted to be field-assembled to form HVAC air conveyance apparatus (e.g., a transition) 100. Each panel may be formed out of sheet metal, such as galvanized steel, aluminum, stainless steel, powder coated steel, pre-painted steel, other iron-carbon alloy combination, or the like, or may be formed out of other materials such as a plastic or other polymer. In some embodiments, air conveyance apparatus 100 may be assembled using, by way of example, only four fasteners.
  • The plurality of panels includes a pair of first quadrilateral panels, end panels 102 and 104. In accordance with various embodiments, each first quadrilateral (end) panel 102 or defines a right-angle (i.e., generally 90 degree) flange 110 a through 110 d extending, generally inward, as illustrated in FIGS. 3 and 4 , from each of a pair of opposite edges 112 a through 112 d. Each of end panels 102 and 104 may also define HVAC unit mating flanges 114 a through 114 d extending from each other edge 116 a through 116 d of each first quadrilateral (end) panel 102 and 104, respectively. As shown in FIG. 5 , at least one of the panels making up air conveyance apparatus (e.g., a transition) 100 may have an HVAC component access door 118. For example. FIG. 5 shows end panel 104 with HVAC component access door 118. Retaining latches 120, as shown in FIG. 5 , or other mechanisms, may be used to removably secure door 118 (closed) on panel 104. For example, as discussed in greater detail below door 118 may be fastened to (peripherical) door frame 122 of panel 104 by means of latches 120. Latches 120 may swivel about a concentric point (on the (insulated) door) with a predetermined rotational degree of freedom.
  • The aforementioned plurality of panels making up HVAC air conveyance apparatus (e.g., a transition) 100 also includes a pair of second quadrilateral panels, side panels 106. As best seen in FIG. 6 , each second quadrilateral (side) panel 106 defines hemmed cleat 108 a or 108 b along each of a pair of opposite edges 124 a and 124 b. While not shown in FIGS. 1 through 7 , side panels 106 may also define HVAC unit mating flanges, similar to HVAC mating flanges 114 of end panels 102 and 104, extending from each other edge 126 a and 126 b of each second quadrilateral (side) panel. Each hemmed cleat 108 is shaped and dimensioned to snuggly (e.g., within a functional snug fit tolerance) receive one of the first quadrilateral panel right-angle flanges 110 to form HVAC air conveyance apparatus 100, with peripheral HVAC unit mating flanges 114 extending from each end of assembled HVAC air conveyance apparatus 100, as best seen in FIGS. 1 and 2 .
  • With attention directed to FIGS. 6 and 7 , each hemmed cleat 108 has, in accordance with various embodiments, hem butt end 128 extending generally perpendicular from face 130 of the respective second quadrilateral (side) panel 106, and along and spaced apart from, respective edge 124 of the second quadrilateral (side) panel. The integral hemmed cleat 108 further defines projecting lip 132 extending from hem butt end 128, generally parallel to face 130 of the respective second quadrilateral (side) panel, toward respective edge 124, and spaced apart from face 130 a distance to define hemmed cleat slot 134. Open hem thickness slot 134 is sized to snug fit receive first quadrilateral (end) panel right-angle flange 110. Each of hemmed cleats 108 may has screw receptive hole 136 defined through projecting lip 132. Screw receptive hole 136 may be pilot hole, sized to receive fastener 138 to secure first quadrilateral panel right-angle flange 110 received in hemmed cleat slot 134 in the hemmed cleat slot, to form HVAC air conveyance apparatus (e.g., a transition) 100. Correspondingly, in some embodiments, each first quadrilateral (end) panel right-angle flange 110 may have a smaller right-angle flange screw receptive pilot hole 140 defined through the right-angle flange. This right-angle flange screw receptive pilot hole is spaced along right-angle flange 110 to align with screw receptive pilot hole 136 defined through projecting lip 132 of hemmed cleat 108 when the right-angle flange is received in hemmed cleat slot 134 defined by the projecting lip. Further, smaller right-angle flange screw receptive pilot hole 140 may be sized (smaller than hemmed cleat screw receptive pilot hole 136) to threadably receive fastener 138 to form HVAC air conveyance apparatus 100. In such embodiments fastener 138 may be a self-threading, self-tapping, self-drilling, or similar screw, or the like. However, in other embodiments, right-angle flange 110 may not define a screw receptive pilot hole, and in such embodiments the fastener may be a drill screw, which may be disposed through hemmed cleat screw receptive pilot hole 136 defined through projecting lip 132 and drill-screwed into right-angle flange 110 to form HVAC air conveyance apparatus 100.
  • Returning to FIGS. 1 through 5 , as noted each panel of the plurality of panels 102, 104 and 106 may, in accordance with embodiments of the present systems and methods, be generally quadrilateral in shape. Some panels may further be trapezoidal in shape. For example, each edge 124 of the pair of opposite edges of each second quadrilateral (side) panel are illustrated as trapezoidal legs for the respective panel. Also, correspondingly, each of other edge 126 of each second quadrilateral side panel are illustrated as trapezoidal bases for each respective panel. In various embodiments each such trapezoidal panel may generally have an isosceles trapezoidal shape. That is, where base angles have the same measure, the two legs, edge pairs 124 a and 124 b are of equal length and each respective panel has reflection symmetry. In some embodiments some or all of the panels may be rectangular (or square) in shape.
  • As shown in FIGS. 1 through 5 , (rigid) insulation (panels) 142, such as certified insulation panels, or the like, may be disposed (e.g., secured, glued, compression fit, pinched, wedged via application of flange after having inserted the insulation, cupped head (weld) pinned, and/or the like) on an inner surface of each panel 102, 104 and 106 of the plurality of panels forming HVAC air conveyance apparatus (e.g., a transition) 100, including, in some embodiments (not shown) on an inner surface of door 118. The insulation panels may have a pressure sensitive adhesive applied foil laminate surface, or other reflective layer such as foil with radiation insulation properties. Alternatively, spray foam insulation may be sprayed on the inner surface of the panels, rather than insulation panels being adhered or affixed thereto. In such embodiments, air purification coating 144 may be disposed on an inner surface of insulation panels 142 and thus on an inner surface of the HVAC air conveyance apparatus 100 in contact with airflow through the installed air conveyance apparatus. In embodiments where insulation panels 142 are not employed an air purification coating may be disposed directly on the inner surface of each panel 102, 104 and 106, of the plurality of panels forming the HVAC air conveyance apparatus, including on an inner surface of door 118, in contact with airflow through the installed air conveyance apparatus. For example, Manganese dioxide, such as in combination with Titanium dioxide, may be used to coat interior surfaces of air conveyance apparatus 100. Manganese dioxide exhibits thermocatalytic activity for the decomposition of organic pollutants. Coupling Titanium dioxide with Manganese dioxide degrades organics further than Titanium dioxide alone, due to the thermocatalytic activity of Manganese dioxide. Further, one or more of the panels (e.g., side panels 106) may include prefabricated (pilot) holes (not shown) which allow an operator or installer to quickly mount an in-duct filter, air purifier, germicidal (ultraviolet (IV)) lamp, disinfecting technology, or the like (not shown) in HVAC air conveyance apparatus 100. These prefabricated (pilot) holes may be accompanied by a “call out” that can be a sticker (over the prefabricated (pilot) holes), metal engraving, laminate, painted, etc. (not shown).
  • With particular attention directed to FIGS. 3 and 5 , as noted, at least one of the panels making up air conveyance apparatus (e.g., a transition) 100 may have an HVAC component access door 118. Figure S shows end panel 104 with HVAC component access door 118.
  • Retaining latches 120 in FIG. 5 removably secure door 118 (closed) to panel door frame 122 of panel 104. As noted, door 118 may be fastened to (peripherical) door frame 122 of panel 104 by means of latches 120, such as by each of latches 120 swiveling about a concentric point 146, on (insulated) door 118) a predetermined amount, such as generally about ninety degrees. Door frame 122 may define door frame slots 148 for receiving the jaw section 150 of latches 120. This door latching mechanism may provide “stay-locked” features to combat pressure variances that may otherwise cause door 118 to (unlatch and) open, unlike prior latches where there is minimal resiliency to forces that may cause the door latch to rotate to an open position when a load is applied to the door, thus triggering the door to leak or freely open during operation. When a positive internal pressure is applied within air conveyance apparatus 100, torque is applied from door frame 122 to latch (arm) 120 that causes it to rotate further into the “locking” direction (i.e., toward inside frame ledge 152). For example, in accordance with embodiments, when assembled and installed conveyance apparatus 100 is exposed to a positive internal pressure acting on the inside of door 118, the edge of the slot (148) in door frame 122 imposes a force onto the arm portion of latch 150. This tangential force acting on the latch arm (150) is a predetermined distance away from fastener 146, thereby acting as a moment arm. The resulting torque thereby applied to latch 120 causes the latch to be rotationally forced into its locking, or securing, position inside of slot 148. This torque can be overcome by a human operator applying an opposing torque on the latch by means of the latch tab, thereby causing the latch to rotate into an “un-locked” position before servicing. Door 118, and frame 122, may be sized such that removal of door 118, by release of laches 120, may, may remove (almost) an entire face of assembled air conveyance apparatus 100. Door 118 is fit to bottom out on inside ledge 152 of door frame 122 so as to seal against leakage of air. The combined, or complementary, geometry of door 188, frame 122 and/or frame ledge 152 may enable compression of insulation 142, such that the insulation acts as a gasket, or enable a flush sheet metal on sheet metal edge between door edge 154 and inside frame ledge 152.
  • In accordance with various embodiments of the present systems and methods, panels 102, 104 and 106 may be prepared for shipment into the field and eventual assembling into air conveyance apparatus (e.g., a transition) 100 by (alternately) stacking the pair of first, quadrilateral (end) panels 102 and 104 with the pair of second quadrilateral (side) panels 106, in various configurations. Thereby, embodiments of the present field-assembled sheet metal air conveyance apparatus save on shipping costs, particularly as compared to one piece, or fully assembled air conveyance apparatus. FIG. 9 is perspective view of example doored end component panel 104 of FIG. 5 , one example side component panel 106 of FIG. 6 , example solid end component panel 104 of FIG. 4 and another example side component panel 106 of FIG. 6 stacked for shipment into the field for filed assembly of air conveyance apparatus 100, according to some embodiments. Also, in accordance with various embodiments of the present systems and methods, panels 102, 104 and 106 may be prepared for shipment into the field and eventual assembling into air conveyance apparatus 10) by stacking the panels with doored end panel 104 and solid (back) end panel 102 are on the outside of the stack with the (two) side panels 106 disposed between, such as illustrated in FIG. 10 .
  • FIG. 11 is flowchart of process 1100 for field-assembly of a sheet metal air conveyance apparatus (100) (and its use in an HVAC system (1000)), according to some embodiments. Initially, the panels (102, 104 and 106) to be used in the air conveyance apparatus (e.g., a transition) are unstacked and at 1105 a pair of first (end) quadrilateral panels (102 and 104) are assembled to a pair of second (side) quadrilateral panels (106) to form a HVAC air conveyance apparatus (100). Assembly at 1105 is carried out by, at 1110, inserting a right-angle flange (110) extending (inward) from each of a pair of opposite edges (112) of each of the first (end)quadrilateral panels (102 or 104) into a hemmed cleat (108) defined along each of a pair of opposite edges (124) of each of a respective one of the second (side) quadrilateral panels; 106. Then, at 1115, each of the first quadrilateral (end) panels (102 and 104) is secured to the respective one of the second quadrilateral (side) panels (106) with a fastener (138) received through a pilot hole (136) defined through a projecting lip (132) of the hemmed cleat (108) of each of the second quadrilateral (end) panels into the right-angle flange (110) extending from the respective one of the first quadrilateral (side) panels. Securing the panels at 1115 may include, by way of example receiving the fastener (138) through the fastener receptive pilot hole (136) defined through the projecting lip (132) of the hemmed cleat (108) of each of the second quadrilateral (side) panels (106) into a screw receptive pilot hole (140) defined in the right-angle flange (110) extending from the respective one of the first second quadrilateral (end) panels (102 or 104).
  • FIG. 12 is a perspective diagrammatic view of HVAC system 1200 employing an embodiment of the present field-assembled sheet metal air conveyance apparatus (e.g., a transition) 100, according to some embodiments. Therein, HVAC system 1200 includes first HVAC unit 1205, which may be an air handling unit, such as a gas or electric furnace, or the like, and second HVAC unit 1210, which may be a set of cased air conditioning evaporator coils, or the like. An embodiment of the present field-assembled sheet metal HVAC air conveyance apparatus 100, such as described above, is disposed between, and secured to, first HVAC unit 1205 and second HVAC unit 1210. Alternatively, first HVAC unit 1205 may be a set of cased air conditioning evaporator coils, or the like, and second HVAC unit 1210 may be an air handling unit, such as a gas or electric furnace, or the like. An embodiment of the present field-assembled sheet metal HVAC air conveyance apparatus 100, such as described above, is disposed between, and secured to, first HVAC unit 1205 and second HVAC unit 1210. In various other embodiments, first unit 1205 and second unit 1210 may be units to be tested in operation together and air conveyance apparatus 100 may act as an air conveyance apparatus between units 1205 and 1210. Likewise, in a laboratory setting, or the like, first unit 1205 and second unit 1210 may be testing units, research units, or the like, joined by air conveyance apparatus 100 to act as an air conveyance apparatus between units 1205 and 1210.
  • Returning to FIG. 11 , to assemble a HVAC system (1200) the assembled HVAC air conveyance apparatus (100) is disposed, at 1120, between a first HVAC unit (1205) and a second HVAC unit (1210), with HVAC unit mating flanges 114 extending from each other opposite edge 116 of each first and/or second quadrilateral panels (102 and 104, or 106) received securable by an open end of each of the first and second HVAC units (1205 and 1210). At 1125 the assembled HVAC air conveyance apparatus (100) is secured between the first HVAC unit (1205) and the second HVAC unit (1210) using a plurality of fasteners (1215) through (a side of the respective HVAC unit and) the HVAC unit mating flanges (114). In accordance with various embodiments of the present systems and methods, the installer may also employ tape with the intentions of sealing and further adhering the air conveyance apparatus (100) in place to the adjacent/connected HVAC appliance (1205 and/or 1210). The installer, operator, or customer may also adhere tape within the inside of the unit(s) (1205 and/or 1210) and/or the air conveyance apparatus (100), in order to further seal the air conveyance apparatus in-line with connected HVAC components (1205 and/or 1210).
  • The order in which each operation of a given method is performed may be changed, and various operations may be added, reordered, combined, omitted, modified, etc. It is intended that embodiment(s) described herein embrace all such modifications and changes and, accordingly, the above description should be regarded in an illustrative rather than a restrictive sense.
  • After assembly the combined components of the unit combine and yield benefits such as improved system efficiency, in that, the assembled system maintains SEER, air flow distribution, heating element exposure, and the like. Further, the combined component unit yield minimized system resistance to the system(s), such as minimized turbulence, minimized minor dynamic pressure loss, minimized flow resistance. Improved service accessibility to the system(s) is also provided in the combined component unit, including a large removable panel (door 118). The combined component unit further yields attenuated sound power of system(s) during operation, so as to provide an increased Sound Transmission Class (STC), increased Noise Reduction Coefficient (NRC), and/or the like. The combined component unit also yields improved resistance to fungi and/or bacteria growth between systems. For example, the combined component unit has low moisture absorption, and thus, eliminates harboring of potential biological life. Improved passive fire protection of system(s) and the associated structure, in the combined component unit is non-combustible. The combined component unit further provides reduced (risk of) chemical exposure and deposition throughout the system(s) and structure, in that certified insulation, or the like, used in the combined component unit is proven to reduce indoor air pollution, and the like.
  • Leak testing was conducted on an embodiment of the present air conveyance apparatus. The apparatus was assembled on site, as is intended to be done by an installer or operator at the scene of installation, and then subjected to internal flow by fans that replicate typical HVAC flow parameters. Using various instrumentation, volumetric flow rates were captured by testing facility provided vent hoods in such a way that recorded air successfully channeled through the apparatus, as well as air that escaped through the confines of the apparatus. Under steady state volumetric flow of 1600 cubic feet per minute, both volumetric flow rates of channeled air and leaked air were recorded simultaneously. The following results were obtained: 7 CFM of leakage during 1600 CFM of flow at an internal positive pressure of 0.23 inches water column (W.C.); 14.5 CFM of leakage during 1600 CFM of flow at an internal positive pressure of 0.51 inches W.C. and 32.25 CFM of leakage during 1600 CFM of flow at an internal positive pressure of 1.27 inches W.C. Thereby, sealing of the assembled air conveyance apparatus, as described above was confirmed.
  • As discussed above, positioning an air tilter in an HVAC system at a location abutting the base of an electric air handling unit places the air filter close to or adjacent the evaporator coil in the air handling unit, which increases the static pressure in the HVAC system. FIG. 13 illustrates a side perspective view of a heating, ventilation and air conditioning (HVAC) system 200 including an air conveyance apparatus (e.g., a transition) 100 that obviates the increase in static pressure caused by conventional air filter placement. In some embodiments, the air conveyance apparatus (e.g., a transition) 100) may be formed of the panels 102, 104, 106 discussed above, and may include any or all of the associated features discussed above with respect to FIGS. 1 to 10 . In other embodiments, the air conveyance apparatus (e.g., transition) 100 may be a pre-fabricated transition with panels that are assembled at a factory (e.g., non-knockdown transition), such that the air conveyance apparatus (e.g., transition) 100 is installed whole in the field. As described above, the air conveyance apparatus (e.g., transition) 100 may be formed of at least four panels (e.g., 102, 104, 106) that together define a perimeter of the air conveyance apparatus (e.g., transition) 100 and an interior thereof. The air conveyance apparatus (e.g., transition) 100 may have a first end configured to be attached to an electric air handler 202 as shown in FIG. 13 , and a second end opposite the first end. The air conveyance apparatus (e.g., transition) 100 may be attached to the electric air handler 202 via clips, snaps, screws, tape, adhesive, or other attaching devices.
  • As shown in FIG. 13 , the HVAC system 200 includes an electric air handler 202. An evaporator coil (or a set of evaporator coils) 204, an air blower 206, and a heater (or furnace) 208 may be provided inside the electric air handler 202. The evaporator coil (or set of evaporator coils) 204 may be any type of coil, and may include, for example, box coils or slab coils, either of which may be in an arrangement that is horizontal, vertical, or a combination thereof. Example box coils include multi-poise A-coils, performance A-coils, and N-coils. The blower 206 may include a motor that forces heated or cooled air passing over the evaporator coil 204 through the ducts (not shown) of the HVAC system 200, and out of vents in rooms throughout the house or building having the HVAC system 200. The heater (or furnace) 208 of the HVAC system 200 may include components, such as an electric heating element, that heat air passing through the electric air handler 202 and circulating through the HVAC system 200.
  • The HVAC system 200 also includes an air filter 210 that may remove impurities such as dust, pet dander and/or bacteria from the air flowing through the HVAC system 200. The inventors of the present invention have discovered that placing an air conveyance apparatus (e.g., a transition) 100 between the air filter 210 and the electric air handler 202 can greatly reduce or eliminate the static pressure that would otherwise exist without a transition. The air conveyance apparatus (e.g., a transition) 100 can provide enough distance between the air filter 210 and the evaporator coil 204 inside the electric air handler 202 to maximize airflow entering the base of the electric air handler 202 without a restriction, in some embodiments, the length of the air conveyance apparatus (e.g., a transition) 100 from a first end thereof that abuts the electric air handler 202 to an opposite second end that abuts the air filter 210 may be at least 8 inches, so that when the air conveyance apparatus (e.g., a transition) 100 is provided between the air filter 210 and the electric air handler 202 the air filter 210 is at least 8 inches away from the electric air handler 202 and the evaporator coil 204 inside the electric air handler 202. This length of the air conveyance apparatus (e.g., a transition) 100 (or distance between the electric air handler 202 and the air filter 210) may allow the air blower 206 to operate without any overworking. In some embodiments, the length of the air conveyance apparatus (e.g., a transition) 100 from a first end thereof to the opposite second end may be 8 inches to 9 inches in order provide better air flow from the air filter 210 on the second opposite end of the air conveyance apparatus (e.g., a transition) 100 to the electric air handler 202 on the first end. However, the length of the of the air conveyance apparatus (e.g., a transition) 100 from a first end thereof to the opposite second end may be greater than 9 inches depending on the design and requirements of the HVAC system 200.
  • The air conveyance apparatus (e.g., a transition) 100 can be sized to the dimensions of the electric air handler 202 and/or the air filter 210 so that airflow between the air handler 202 and the air filter 210 can be maximized and the static pressure minimized. Conversely, the air filter 210 can be sized to match the dimensions of the air conveyance apparatus (e.g., a transition) 100. For instance. FIG. 13 shows an embodiment in which the first end of the air conveyance apparatus (e.g., a transition) 100 has a perimeter that is smaller than the perimeter of the second opposite end thereof, so that the perimeter of first end is sized to match the dimension of the smaller opening of the electric air handler 202. The larger perimeter of the second opposite end of the air conveyance apparatus (e.g., a transition) 100 matches the dimension of the larger perimeter of the air filter 210. Sizing these components to match or fit the dimensions of each other as described in the example above can eliminate the offset between the air filter 210 and the electric air handier 202, which would otherwise result in restricted air flow and thus increased static pressure. In some embodiments, the air conveyance apparatus (e.g., a transition) 100 may include the air filter 210, such that the air filter 210 is a part of the air conveyance apparatus (e.g., a transition) 100. In some of those embodiments, the air filter 210 may be a replaceable part of the air conveyance apparatus (e.g., a transition) 100. The air filter 210 may be attached to the air conveyance apparatus (e.g., transition) 100 via clips, snaps, screws, tape, adhesive, or other attaching devices.
  • FIG. 13 shows that the HVAC system 200 may also include an air return unit 212 on a side of the air filter 210 that is opposite the side that abuts the air conveyance apparatus (e.g., a transition) 100. The air return unit 212 may allow the air in the house or building having the HVAC system 200 to return to the system for continued heating or cooling.
  • In addition, one of the panels 104 of the air conveyance apparatus (e.g., a transition) 100 may include the removable access door 118 discussed herein. The removable access door 118 may allow for access into the interior of the air conveyance apparatus (e.g., a transition) 100 for cleaning and/or inspection of the evaporator coil 204 and/or the air filter 210 without having to disassemble the component parts of the HVAC system 200. Further, instruments that measure static pressure can be inserted into the air conveyance apparatus (e.g., a transition) 100 through the opening in the panel 104 provided by the removable access door 118.
  • In some embodiments, one or more of the panels 102, 106 of the air conveyance apparatus (e.g., a transition) 100 may include one or more access ports 214 opening into the interior of the air conveyance apparatus (e.g., a transition) 100. The access ports 214 may be pre-punched holes of any kind. The access ports 214 may permit access for a variety of reasons, e.g., for installing and/or mounting of: static pressure measuring devices; air flow and air quality metering devices; and temperature and other types of probes or metering devices for testing temperature and other metrics within the HVAC system 200. The mounting may be accomplished, for example, by any fastening devices known or available. In addition, one or more of the panels 102, 106 of the air conveyance apparatus (e.g., a transition) 100 may include a mounting port 216 opening into the interior of the air conveyance apparatus (e.g., a transition) 100. The mounting port 216 may be a pre-punched hole of any kind, and may permit access for and mounting of an ultraviolet light and baffle assembly 218 within the interior of the air conveyance apparatus (e.g., a transition) 100. The mounting may be accomplished, for example, by any fastening devices known or available.
  • FIG. 14A illustrates the main components of the ultraviolet light and baffle assembly 218 according to an embodiment. In the embodiment, the ultraviolet light and baffle assembly 218 includes an ultraviolet light emitter 219 or other ultraviolet radiant tube device, and a baffle 220 that is configured to be detachably attached to the ultraviolet light emitter 219. The baffle 220 may be detachably attached to the ultraviolet light emitter 219 via. e.g., clips 221 that grip ends or other portions of the ultraviolet light emitter 219. FIG. 14B is a perspective view of the baffle side of the assembled ultraviolet light and baffle assembly 218. The baffle side is adapted to face the filter 210 when mounted within the air conveyance apparatus (e.g., a transition) 100 to protect the air filter 210 from being degraded by the ultraviolet light from the ultraviolet light emitter 219. Meanwhile, the ultraviolet light from the ultraviolet light emitter 219 may eliminate mold and mildew, kill viruses and bacteria, and reduce odors, thus increasing the efficiency of the HVAC system 200 and improving the quality of the indoor air in the HVAC system 200. FIG. 14C is a perspective view of the ultraviolet light side of the assembled ultraviolet light and baffle assembly 218. The ultraviolet light side is adapted to face the evaporator coil(s) 204 of the electric air handler 202 when mounted within the air conveyance apparatus (e.g., a transition) 100 to help clean the evaporator coil(s) 204 and air that passes through the HVAC system naturally.
  • While the embodiment of FIG. 13 shows the removable access door 118 on a side panel of the air conveyance apparatus (e.g., a transition) 100, FIG. 15 illustrates another embodiment of the HVAC system 200 in which the removable access door 118 on a top panel of the air conveyance apparatus (e.g., a transition) 100. Other components of the HVAC system 200 shown in FIG. 15 may be the same or similar as in the system shown and described herein with respect to FIG. 13 .
  • FIG. 16 is a diagrammatic view of a method 300 of transitioning within an HVAC system 200 employing an air conveyance apparatus (e.g., a transition) 100 according to some embodiments. The method 300 may begin after the field assembly process 1100 shown in FIG. 11 and described above has been completed. At step 302 of the method, a first opened end of the assembled air conveyance apparatus (e.g., a transition) 100 is positioned at a first opened end of the electric air handler 202, which air handler includes the evaporator coil(s) 204, the air blower 206, and the heater (or furnace) 208 as discussed above. At step 304, a first side of the air filter 210 discussed herein is positioned at a second opened end of the air conveyance apparatus (e.g., a transition) 100, the second opened end being opposite the first opened end of the air conveyance apparatus (e.g., a transition) 100. The air filter 210 may be positioned at the second opened end of the air conveyance apparatus (e.g., a transition) 100 to be at least 8 inches away from the air handler 202 as discussed herein. As also discussed herein, one of the panels 104 of the air conveyance apparatus (e.g., a transition) 100 may be provided with the removable access door 118 that opens to allow access into the interior of the air conveyance apparatus (e.g., a transition) 100. In addition, one of the panels 102, 206 of the air conveyance apparatus (e.g., a transition) 100 may be provided with one or more access ports 214 opening into the interior of air conveyance apparatus (e.g., a transition) 100. At step 306, an opened end of the air return unit 212 may be positioned on a second side of the air filter 210, the second side being opposite the first side of the air filter 210. At step 308, an ultraviolet light and baffle assembly 218 may be mounted within the air conveyance apparatus (e.g., a transition) 100. A baffle 220 may be positioned on the ultraviolet light 219 to face the air filter 210 to protect the air filter 210 from being degraded by ultraviolet light.
  • Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

Claims (17)

What is claimed is:
1. An air conditioning system comprising:
an air handler;
an evaporator coil in the air handler;
a blower in the air handler;
a heater in the air handler;
an air filter; and
a transition between the air handler and the air filter.
2. The air conditioning system according to claim 1, further comprising:
an air return unit on one side of the air filter.
3. The air conditioning system according to claim 1, wherein
the transition comprises a panel that includes an access door that opens to allow access into an interior of the transition.
4. The air conditioning system according to claim 1, wherein
a length of the transition is at least 8 inches so that the air filter is at least 8 inches away from the air handler.
5. The air conditioning system according to claim 1, wherein
the transition includes a panel comprising one or more access ports opening into the interior of the transition.
6. The air conditioning system according to claim 1, further comprising:
an ultraviolet light mounted within the transition; and
a baffle on the ultraviolet light, wherein the baffle is positioned to face the air filter to protect the air filter from being degraded by ultraviolet light.
7. A transition for an air conditioning system, the transition comprising:
at least four panels that together define a perimeter of the transition and an interior of the transition;
a first end configured to be attached to an air handler;
a second end opposite the first end; and
an air filter at the second end, wherein
at least one of the at least four panels includes an access door that opens to allow access into the interior of the transition.
8. The transition according to claim 7, wherein
a length of the transition from the first end to the second end is at least 8 inches.
9. The transition according to claim 7, wherein
at least one of the at least four panels includes one or more access ports opening into the interior of the transition.
10. The transition according to claim 7, wherein
the at least four panels are configured to be detachably attached to each other to allow the transition to be field assembled at a job site.
11. The transition according to claim 7, wherein
wherein at least one of the at least four panels includes a mounting port for mounting an ultraviolet light and baffle within the interior of the transition.
12. A method of transitioning within an air conditioning system, the method comprising:
positioning a first opened end of a transition at a first opened end of an air handler comprising an evaporator coil, a blower, and a heater; and
positioning a first side of an air filter at a second opened end of the transition, the second opened end being opposite the first opened end of the transition.
13. The method according to claim 12, further comprising:
positioning an opened end of an air return unit on a second side of the air filter, the second side being opposite the first side.
14. The method according to claim 12, further comprising:
providing a panel of the transition with an access door that opens to allow access into an interior of the transition.
15. The method according to claim 12, wherein
the air filter is positioned at the second opened end of the transition to be at least 8 inches away from the air handler.
16. The method according to claim 12, further comprising:
providing a panel of the transition with one or more access ports opening into the interior of the transition.
17. The method according to claim 12, further comprising:
mounting an ultraviolet light within the transition, wherein a baffle is positioned on the ultraviolet light to face the air filter to protect the air filter from being degraded by ultraviolet light.
US18/130,700 2021-12-08 2023-04-04 Field-assembled air conveyance apparatus, and systems and methods utilizing air conveyance apparatus Pending US20230235918A1 (en)

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