Air Handler Devices with U-Bend Design

The subject patent application is a continuation of, and claims priority to each of, U.S. patent application Ser. No. 18/516,068, filed Nov. 21, 2023, and entitled “AIR HANDLER DEVICES WITH U-BEND DESIGN”, which is a continuation of U.S. patent application Ser. No. 18/314,420 (now U.S. Pat. No. 11,846,434), filed May 9, 2023, and entitled “AIR HANDLER DEVICES WITH U-BEND DESIGN”, which is a continuation-in-part of U.S. patent application Ser. No. 17/219,531 (Now U.S. Pat. No. 11,674,696), filed Mar. 31, 2021, and entitled “AIR HANDLER DEVICES WITH IMPROVED DESIGN AND FUNCTIONALITY”, which is a continuation of U.S. patent application Ser. No. 16/930,635 (now U.S. Pat. No. 11,346,564), filed Jul. 16, 2020, and entitled “HVAC DEVICES WITH IMPROVED DESIGN AND FUNCTIONALITY”, the entireties of which are hereby incorporated by reference herein.

The present disclosure is directed to improved designs for air handler devices, and more particularly to device designs comprising a U-bend design.

In several ways, modern air handler devices rely on structural designs or techniques that are many decades old without adequate improvement over that time. As such, improved designs, including those using advanced aero-acoustical physics, can provide much needed and long awaited benefits.

The following presents a summary to provide a basic understanding of one or more embodiments of the disclosure. This summary is not intended to identify key or critical elements or delineate any scope of the particular embodiments or any scope of the claims. Its sole purpose is to present concepts in a simplified form as a prelude to the more detailed description that is presented later.

According to an embodiment of the present disclosure, an evase device is presented. The evase device can comprise a housing that encompasses a channel. The channel can extend in a longitudinal direction from a first side of the housing to a second side of the housing. The evase device can comprise a first opening that is situated at the first side of the housing. The first opening can be configured to receive a flow of a fluid discharged by a fan. The evase device can comprise a second opening that is situated at the second side of the housing. The second opening can be configured to discharge the flow into a duct. At the second side, the housing can have a rounded corner determined to mitigate a reverse flow of the fluid at corners of the duct.

According to an embodiment of the present disclosure, an intake device is presented. The intake device can be, e.g., intake air (or another fluid) for an HVAC system (or another system), and can operate with greatly reduced noise reduction. The intake device can comprise an intake duct. The intake duct can comprise a first opening by which a fluid enters the intake duct and a second opening by which the fluid exits the intake duct. The first opening and the second opening can be substantially circular about a longitudinal axis of the intake duct. A first circumference of the first opening can be larger than a second circumference of the second opening. The intake device can further comprise a top cover. The top cover can prevent the fluid from entering the intake duct in a direction along the longitudinal axis (e.g., vertical). However, the top cover can be situated a distance from the first opening, e.g., to permit the fluid to enter the intake duct in a radial direction that is radial about the longitudinal axis (e.g., horizontal). The intake device can further comprise an inner funnel that can be situated within the inner passageway of the intake duct. The inner funnel can comprise an upper portion that couples to the top cover and a lower portion that extends into the passageway. The inner funnel can comprise an outer surface that spans the upper portion and the lower portion. The outer surface can be sloped, causing the flow of the fluid entering the intake duct in the radial direction to change to the direction along the longitudinal axis.

According to an embodiment of this disclosure, an aero-acoustical fan intake device is presented. The fan intake device can be, e.g., represent an intake for air (or another fluid) for a fan of an HVAC system (or another system), and can operate with greatly reduced acoustical (e.g., noise) reduction without significant aerodynamic loss. The fan intake device can comprise an inlet face. The inlet face can comprise an inlet opening configured to receive a flow of a fluid. The fan intake device can further comprise a discharge face. The discharge face can comprise a discharge opening configured to discharge the flow of the fluid. Further still, the fan intake device can comprise a housing. The housing can encompass a flow channel that extends from the inlet opening to the discharge opening. Significantly, a cross-sectional area of the flow channel can vary between the inlet opening and the discharge opening in a manner that is determined to cause the flow of the fluid through the flow channel to continuously accelerate from a first location of the channel to the discharge opening.

According to a first embodiment of this disclosure, an air handler device is presented. The air handler device can comprise a mixing plenum. The mixing plenum can be configured to receive multiple flows of air from multiple different ducts that feed the mixing plenum. The air handler device can comprise a fan device. The fan device can be configured to receive a mixing plenum flow from the mixing plenum and to discharge a supply flow. The air handler device can further comprise a supply plenum. The supply plenum can be configured to receive the supply flow from the fan device. The supply plenum can comprise a plurality of duct interfaces. The duct interfaces can be respectively configured to interface with a different one of a plurality of supply ducts. The supply plenum can further comprise a plurality of thermal transfer units comprising a first thermal transfer unit and a second thermal transfer unit. The plurality of thermal transfer units can be respectively situated in different ones of the plurality of duct interfaces. Furthermore, the first thermal transfer unit can be configured to heat a first air flow concurrently with the second thermal transfer unit cooling a second air flow.

According to a second embodiment of this disclosure, another air handler device is presented. This air handler device (as well as the first air handler device) can be part of an HVAC product. The air handler device can be configured to circulate a flow of air within an HVAC system situated at a site the HVAC product is to be installed. The air handler device can comprise a top surface that is, relative to an installation at the site, on top of the air handler device. The air handler device can have a first height that is, relative to the installation, a height of the air handler device. The HVAC product can further comprise a heat exchange device that can be configured to exchange heat with the flow of air. The heat exchange device can have a second height that is, relative to the installation, a height of the heat exchange device. Further, the heat exchange device can be situated on the top surface of the air handler device, resulting in the HVAC product having a total height that is, relative to the installation, determined to be less than or equal to a defined height constraint

In some embodiments, elements described in connection with the systems and apparatuses above can be embodied in different forms such as a computer-implemented method of fabrication, or another form.

The disclosed subject matter is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed subject matter. It may be evident, however, that the disclosed subject matter may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing the disclosed subject matter.

Referring now to the drawings, with initial reference to, a block diagramof two example views of an evase are depicted in accordance with certain embodiments of this disclosure. In the HVAC domain, an evase can operate as a duct transition. For instance, the evase can connect a fan outlet, typically circular in shape to match fan impeller sweep, to a supply duct that is typically larger in size and rectangular in shape. This duct size and shape transition can lead to undesired consequences, some of which are discussed in connection with evase.

The left side ofillustrates a longitudinal axis perspective of evase, for instance a view as seen from the duct, with the longitudinal axis that extends into the page and intersects at point. Evasecan comprise inletthat is circular in shape and can be configured to receive a flow of a fluid discharged by a fan (not shown). Evasecan further comprise outletthat is rectangular in shape and can be configured to discharge the fluid into a supply duct (see duct).

The right side ofdepicts evasefrom the perspective of a cross-section along diagonal linethat runs from the top-right corner to the bottom-left corner, which can represent a projected diagonal view. Circular inletreceives a flow of fluid from the fan, which is illustrated by fluid flow lines(dashed lines). Because outletis larger in size, the fluid gradually expands through the interior chamber of evase. This gradual expansion continues well into duct.

As shown, a longest distancebetween inletand outletis represented by some point on the circular ring of inletto a rectangular corner of the outlet. Distancecan represent a significant factor in the efficacy of evasebecause it can approximately represent a potentially longest path for the flow of fluid through evase. Based on ordinary geometric principles, angleis a function of and therefore constrained by evase lengthand distance.

Further, due to the velocity of the fluid discharged by the fan, a common situation arises in other evase devices such as evasein which angleis too large to facilitate fluid flow to flow along longest path. As a result, significant reverse flowarises. This reverse flowleads to a number of disadvantages.

For example, in conventional systems, a decrease in kinetic energy between the fan discharge and larger downstream duct is entirely lost, being converted into heat carried by the flow. The effective fan efficiency is greatly reduced, in some cases by nearly 50%. To account for this loss, a larger fan motor than would otherwise be required is generally utilized and/or the fan is operated at a higher revolutions per minute (RPM) than needed otherwise. Generally, higher operating RPM's mean a noisier equipment room and reduced motor lifetime.

Further, because HVAC systems are generally configured to supply cool air to the building, the heating of the flow outlined above requires either increasing the total flow to obtain the same cooling effect from the warmer air or lowering heat rejection temperature to compensate for that extra heat. In any case the extra heat places an additional burden on the thermal rejection system, which must also extract heat equal to the heating caused by the evase energy loss. Poor evase efficiency is paid for by increased operating cost for the fan and heat rejection sections.

Further still, practical HVAC systems rarely have sufficient space (e.g., 5 to 10 duct diameters of duct length) required for the flow to straighten out downstream of the ineffective evase. In practice the flow is often turned and/or divided almost immediately following the evase. The nonuniform flow increases losses in turns and will not follow the geometry of a split unless downstream dampers are feathered to limit flow to the favored channel, contributing to additional losses to the system together with additional noise from dampers up in the ceiling space, which can adversely affect occupants below the dampers.

Referring now to, a block diagramof two example views of an improved evase design are depicted in accordance with certain embodiments of this disclosure. In that regard, a longitudinal axis perspective of evaseis illustrated on the left side of, while the right side ofdepicts a cross-section along diagonal linethat runs from the top-right corner to the bottom-left corner, which can represent a projected diagonal view. Evasecan comprise housingshown in dashed lines. Housingcan encompass a channel that extends in a longitudinal direction from a first side (e.g., inlet side) of housingto a second side (e.g., outlet side) of housing. A length of this channel is illustrated by reference numeral.

Evasecan further comprise first openingsituated at the first side of housing(e.g., inlet side). First openingcan be configured to receive a flow(e.g., indicated by dashed lines) of a fluid discharge by a fan. As depicted, first opening can have a circular shape that can match or scale to the fan or impeller blades of the fan, however first openingcan be any suitable shape.

Evasecan further comprise second opening. Second openingcan be situated at the second side of housing(e.g., outlet side). Second openingcan be configured to discharge flowinto duct. Advantageously, at second opening, housingcan have rounded corners. Rounded cornerscan be configured to or determined to mitigate a reverse flow (e.g., see reverse flowof) at corners of duct. In some implementations, reverse flowcan be entirely prevented, while in other cases reverse flowcan be significantly reduced, resulting in much smaller effective reverse flow shown here at reference numeral.

In more detail, ductcan have a rectangular shape and corners of ductcan be squared corners. As evasecan be coupled to ductand/or serve as an interface to duct, corners of an exterior portion of housingcan be rectangular shaped that can be variably sized to correspond to or match a size and shape of duct. However, an interior portion of housingcan exhibit rounded corners.

By way of comparison with evaseof, due to rounded corners, lengthis shorter than the corresponding lengthof, the latter of which extends to the corner of duct. Assuming channel lengthis approximately the same as length(which is often a physical constraint of a given system or customer site), one result of lengthbeing shorter is that angleis less than angle. As such, flowcan readily flow through a larger volume of both the evase channel and ductinstead of being more inclined flow in regions not much larger than openinguntil much farther downstream of duct, as shown in.

In some embodiments, a shape of rounded cornersis determined or designed based on a Reynolds number calculation. It is appreciated that the fluid discharged by the fan can have a velocity pressure that is converted to static pressure less an impact loss. In some embodiments, the shape of rounded cornerscan be determined to reduce this impact loss and therefore cause a net positive change in static pressure.

It is appreciated that the shape of rounded cornersin this example is representative of a square shaped housingwith a suitably sized duct. In other embodiments, housingand/or ductsmight be different shapes, for example, rectangular in shape. In those cases, and further based on a difference between sizes or shapes of housingand duct, the prominence of rounded cornerscan differ from what is depicted in this example. For instance, consider the case of a more rectangular shape in which a width of the longitudinal axis perspective is greater than the height. In that case, rounded cornerscan have a similar height to what is depicted, but with a greater length. At some threshold, the rounded cornersmay meet one of the two neighboring rounded corners. For example, both of the rounded cornersat the top of the figure can intersect with those at the bottom of the figure, causing the shape of the opening to resemble a flattened oval. In other embodiments, such as when a given rounded cornerintersects with both neighboring rounded corners, the shape of the opening can resemble a circle. These different shapes, as well as other suitable shapes are considered to be within the scope of the disclosed subject matter.

To continue the above description, when comparing evase(e.g., comprising squared corners) to evase(e.g., comprising rounded corners), a change in static pressure (ASP) is expected to be zero. In contrast, ASP for evasecan be a function of a difference between a velocity pressure (VP) at first opening(e.g., VP) and a VP within the ductat some defined distance downstream of evase(e.g., VP). As one example, ASP can equal 8*(VP−VP). This can reduce utilized fan horsepower by 20-30%, sometimes allowing selection of the next smaller motor size, which can significantly reduce costs and overhead.

Furthermore, certain disadvantages listed above with respect to other systems (e.g., evase) are reversed for improved evase. For instance, evasecan result in reduced fan RPM's and installed horsepower, quieter equipment rooms, longer motor life, and more even discharge flow so that elbows and splitters work more efficiently. In addition, heat rejection load can be reduced. Both fan and heat rejection operating costs are reduced.

While not shown here, in some embodiments, evasecan further comprise an intermediate baffle that can further enhance advantages discussed herein, which is further detailed in connection with. Further, in some embodiments, some portions of housingor another housing or container can be filled with a material that absorbs sound, which is also discussed in more detail in connection with.

As previously noted first openingcan have a circular or annular shape. In some embodiments, this circular or annular shape can have a diameter that corresponds to or matches an impeller hub diameter of the fan. In some embodiments, the fan can be mounted to or embedded in housing, which is further detailed in connection with

Turning now to, a three-dimensional graphical depiction of a first example improved evase deviceis illustrated in accordance with certain embodiments of this disclosure. As illustrated, evase devicecan comprise housingthat encompasses a channel (e.g., in which fluid flows) that extends in a longitudinal direction. This longitudinal direction can be represented by longitudinal axisand the channel can extend from first sideof housing(e.g., right hand side) to second sideof housing(e.g., left hand side).

Evase devicecan comprise first openingsituated at first sideof housing. First openingcan be configured to receive flowof a fluid discharged by a fan. Evase devicecan further comprise second openingsituated at second sideof housing. Second openingcan be configured to discharge flowinto a duct. Beneficially, at second side, housinghas one or more rounded corners. Rounded cornerscan be determined to mitigate a reverse flow of the fluid that might otherwise occur at corners of the duct.

Referring now to, a three-dimensional graphical depiction of a second example improved evase deviceis illustrated in accordance with certain embodiments of this disclosure. As illustrated, evase devicecomprises all or a portion of example evase device. In this view rounded cornerscan be seen. In addition, evase devicecomprises an exterior housingthat encloses evase deviceand other elements. Housingcan further include a material that absorbs or mitigate sound.

In addition, evase devicecan further include an intermediate baffle. Intermediate bafflecan further improve functional advantages such as improving mitigation of reverse flow. Intermediate bafflecan operate reduce necessary length (e.g., evase channel length) of the evase by about half. For example, by including intermediate baffle, evase channel lengthcan be about half the size as what might otherwise be needed in order to effectuate proper flow with mitigated reverse flow. Such can be a significant advantage, particularly in implementations where there is not a lot of space at the installation site for an evase device

Intermediate bafflecan operate to guide the outer portion of the flow to expand at nearly twice the angle (e.g., angle) otherwise possible without engendering complete flow separation from the rapidly expanding outer boundaries. Intermediate bafflecan also provides superior sound attenuation by placing additional absorption material in the middle of the flow where the outer and inner sound absorbing materials are least effective. As illustrated, intermediate bafflecan also exhibit or comprise rounded corners. Rounded cornersof intermediate bafflecan exhibit the same or a different gradient as rounded cornersof evase device, either of which can be based on a Reynolds number calculation.

Turning now to, a graphical depiction illustrates systemthat can be representative of an example exploded view of evase devicein accordance with certain embodiments of this disclosure. In this example, additional elements of evase devicecan be identified. It is appreciated that evase devicecan contain all or only a portion of elements described in connection with system, which are intended to be exemplary or representative, but also non-limiting. For instance, other elements may be present and certain elements discussed here may be optional or excluded.

Systemcan include evase, which can be substantially similar to evase. At opposing sides of evase, the device can be coupled to interface elements such as annular fan interface elementand rectangular duct interface element. Elementsandcan essentially line opposing openings (e.g., first openingand second opening. Hence, rectangular duct interface elementcan exhibit rounded corners that match or correspond to rounded corners.

Systemcan include intermediate baffle, which can be substantially similar to intermediate baffle. Likewise intermediate bafflecan be coupled to interface elementsandthat are situated on opposing sides of intermediate baffle. When assembled, intermediate bafflecan fit inside evase deviceand a central axis (e.g., longitudinal axis) can be include central pod. Sizing for central podcan match the impeller hub, eliminating the impact loss that otherwise occurs at the impeller hub region, and which can be built into the fan curves according to testing. A fan tested at, e.g., 78% efficient may become, e.g., 83% efficient, representing a 5-10% increase in efficiency. Central podmay be conical in shape, resulting in a smaller area at the discharge, further reducing impact losses. The net effect of central podcan translate to an 80% to 90% recovery of the impact loss behind the impeller hub.

Support for the assembled elements at the intake side can be provided by support elements, while similar support at the opposing side can be provided by support elements. Rectangular frameand intake side face platecan further be assembled.

On the opposing side (e.g., discharge side), L-shaped support elementsand support rod elementscan be assembled. These support elements (e.g.,,, and) can provide support, such as support for elements fitted inside housing, which can include evase, intermediate baffle, and central pod. Systemcan further include discharge side rectangular frame, discharge side face plateand top frame.

With reference now to, a graphical depiction illustrates systemthat can be representative of an example exploded view of evase devicewith an integrated fan in accordance with certain embodiments of this disclosure. Systemcan include all or a portion of elements detailed in connection with system, including all or some portion of elements-. In addition, systemcan further include an integrated fan.

For example, systemcan include fan hubthat can couple to all or a portion of central pod, interface elements,, intermediate baffle, and/or evase. As illustrated, impeller housingcan include straightening vanes and a sleeve having an impeller hub diameter to contain the motor. Systemcan further include motorand impeller. Hence, in some embodiments, housingof evase system, or elements therein such as intermediate baffleor evase, can operate as a housing for certain elements of the fan, such as motor.

As can be observed, in some embodiments, motorcan be situated within the interior channel of evase deviceand/or within an interior channel of intermediate baffle, which itself can be situated within the interior channel of evase device. In some embodiments, central podcan have dimensions that match or correspond to dimensions of motor. In some embodiments, central podcan contain all or portions of motorsuch that central podcan match up right behind the impeller hub.

Advantageously, situating fan elements (e.g., motor, etc.) inside the interior channel of evase devicecan result in significant space savings, which can further increase the efficacy of evase devices detailed herein. For example, turning back, flowcan be considered to begin just behind location of impeller. In other systems, where the fan motor is farther upstream, the length of the motor reduces the available length for evasebecause an evase channel lengthcan be constrained by the locations of the fan and duct. However, by placing motorwithin the channel of evase(or other evase devices detailed herein), evase channel lengthcan be increased by a similar amount. As such, anglecan be decreased, which can further prevent or mitigate reverse flowas well as further other advantages detailed herein.

illustrate various methodologies in accordance with the disclosed subject matter. While, for purposes of simplicity of explanation, the methodologies are shown and described as a series of acts, it is to be understood and appreciated that the disclosed subject matter is not limited by the order of acts, as some acts can occur in different orders and/or concurrently with other acts from that shown and described herein. For example, those skilled in the art will understand and appreciate that a methodology could alternatively be represented as a series of interrelated states or events, such as in a state diagram. Moreover, not all illustrated acts can be required to implement a methodology in accordance with the disclosed subject matter. Additionally, it should be further appreciated that the methodologies disclosed hereinafter and throughout this specification are capable of being stored on an article of manufacture to facilitate transporting and transferring such methodologies to computers.

illustrates a flow diagramof an example, non-limiting method for fabricating an evase device in accordance with one or more embodiments of the disclosed subject matter. For example, a device comprising a processor can perform certain operations. Examples of said processor as well as other suitable computer or computing-based elements, can be found with reference to, and can be used in connection with implementing one or more of the devices or components shown and described in connection with figures disclosed herein.

At reference numeral, the device comprising the processor can facilitate forming a housing that encompasses a channel. The channel can extend in a longitudinal direction from a first side of the housing to a second side of the housing. As used herein, the term ‘forming’ can comprise any suitable structural manipulation of a material or element including concepts directed to creating a material or element, structurally manipulating a material or element, or assembling a material or element.

At reference numeral, the device can facilitate forming a first opening in the housing that is situated at the first side of the housing, wherein the first opening is configured to receive a flow of a fluid discharged by a fan. In some embodiments, the first opening can be sized to match or correspond to certain elements of a fan, such as an impeller of the fan. In some embodiments, the first side of the housing can be coupled to the fan.

At reference numeral, the device can facilitate forming a second opening in the housing that is situated at the second side of the housing, wherein the second opening is configured to discharge the flow of a fluid into a duct. In some embodiments, the second opening can be sized to match or correspond to a duct. In some embodiments, the second side can be coupled to the duct.

At reference numeral, the device can facilitate forming rounded corners at the second side of the housing, wherein the rounded corners are determined to mitigate a reverse flow of the fluid at corners of the duct. Methodcan proceed to insert A, which is further detailed in connection with, or terminate.