Abstract:
A heating arrangement is provided for use in an air handling unit. The heating arrangement includes at least one heating device to be disposed in the airflow of an air handling unit. A base is configured to support the at least one heating device and a first guide member to be mounted on a structural component inside the air handling unit. A second guide member is mounted on the base, the second guide member being configured to slidably engage the first guide member. Sliding engagement of the first guide member and the second guide member positions the at least one heating device to an installed position inside the air handling unit.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention is directed to a heat kit installation, and more particularly, is directed to a heat kit installation mounting device for use with an air handling unit.  
       BACKGROUND OF THE INVENTION  
       [0002]     Air handling units (AHUs) are one of several components in cooling and heating systems. They are an important component as the AHU houses a number of components used in the system to provide forced air for climate control in a particular structure. AHU components typically include motors, heating/cooling coils, and blowers as well as the required interface connections to effect such climate control.  
         [0003]     As discussed above, an AHU compartment or blower compartment includes adjacent walls partially surrounding a blower with support structure extending transversely to the blower. Transverse members extending between support structures structurally secure the blower against an aperture formed in the wall so that during operation of the blower, air is propelled from the blower compartment for circulation of the air to the structure. Some AHUs are provided with what is commonly referred to as an electric heat kit or heat kit. A heat kit typically includes electric resistance heating elements and associated components required for operation. The electric resistance heating elements and associated components are typically secured to a single support structure within the AHU.  
         [0004]     The heat kit is typically installed into the AHU so that the electric resistance heating elements are disposed adjacent to a blower. The electric resistance heating elements heat the air that is circulated through a structure by the blower. To install a heat kit inside the AHU, the heat kit is typically directed inside a compartment containing the blower. The portion of the heat kit containing the electric resistance heating elements is then inserted through an opening in a wall separating the compartment containing the blower from an adjacent compartment downstream from the blower compartment. The clearance between the opening and the electric resistance heating elements is minimal, since it is desirable to maximize the surface area of the electric resistance heating elements with respect to the cross sectional surface area of the adjacent compartment to maximize the effectiveness of the electric resistance heating elements. However, the minimal clearance between the compartmental wall opening and the electric resistance heating elements results in a difficult installation of the heat kit, which is further complicated due to the susceptibility to damage to the electric resistance heating elements. The installation is yet further complicated when performed as a retrofit to an operational AHU, in which the blower can be positioned in non-ergonomic orientations that are poorly lit.  
         [0005]     Some heat kits include an aperture in a distal portion of a blower compartment of an AHU that engages a rod secured to the heat kit when the heat kit is properly installed to secure the heat kit in position. However, this construction does nothing to simplify the installation of the heat kit, as the electric heating elements must still be painstakingly guided through the opening in the compartmental wall of the AHU.  
         [0006]     What is needed is a heat kit mounting device that greatly simplifies the installation of a heat kit inside an AHU, while providing a reduction in both installation time and significantly reducing the opportunity to damage the electric resistance heating elements during installation.  
       SUMMARY OF THE INVENTION  
       [0007]     The present invention relates to a heating arrangement for use in an air handling unit including at least one heating device to be disposed in the airflow of an air handling unit. A base is configured to support the at least one heating device and a first guide member is to be mounted on a structural component inside the air handling unit. A second guide member is mounted on the base, the second guide member being configured to engage the first guide member. Engagement of the first guide member and the second guide member positions the at least one heating device to an installed position inside the air handling unit.  
         [0008]     The present invention further relates to a method of installing a heating arrangement in an air handling unit. The steps include providing at least one heating device to heat an airflow of an air handling unit and providing a base configured to support the at least one heating device, the base including a first guide member. The method further includes mounting a second guide member on a structural component inside the air handling unit, and aligning the first guide member with the second guide member to engage the second guide member. The method further includes directing the first guide member into engagement with the second guide member to position the at least one heating device in an installed position inside the air handling unit.  
         [0009]     An advantage of the present invention is that it is inexpensive to manufacture.  
         [0010]     A further advantage of the present invention is that it requires few parts.  
         [0011]     A still further advantage of the present invention is that it reduces the time required to install a heat kit inside an AHU.  
         [0012]     An additional advantage of the present invention is that it simplifies installation of a heat kit inside an AHU.  
         [0013]     A further advantage of the present invention is that it reduces the opportunity to damage the electric resistance heating elements during installation of a heat kit inside an AHU.  
         [0014]     Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]      FIG. 1  is an enlarged, partial perspective view of a AHU blower compartment including a guide of the present invention.  
         [0016]      FIGS. 2 and 3  are opposed perspective views of a heat kit of the present invention.  
         [0017]      FIGS. 4-6  are perspective views of embodiments of a heat kit of the present invention.  
         [0018]      FIG. 7  is an enlarged, partial perspective view of a partially installed heat kit of the present invention.  
         [0019]      FIG. 8  is an enlarged, partial perspective view of embodiments of a fully installed heat kit of the present invention.  
         [0020]      FIG. 9  is a partial end view of an alternate embodiment of a heat kit bracket engaged with a guide of the present invention.  
         [0021]      FIG. 10  is a partial end view of a further alternate embodiment of a heat kit bracket engaged with a guide of the present invention. 
     
    
       [0022]     Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are typically not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention.  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0023]      FIG. 1  illustrates one embodiment of a guide  30  in an AHU compartment  10 . As discussed above, the AHU compartment or blower compartment  10  includes adjacent walls  15 ,  16 ,  18  partially surrounding a blower  12  with support structures  20 ,  22  extending transversely to the blower  12 . Transverse members  24 ,  26  extending between support structures  20 ,  22  structurally secure the blower  12  within the blower compartment  10  so that during operation of the blower  12 , air is propelled from the blower compartment  10  for circulation of the air to the structure. Guide  30  facilitates easy installation of a heat kit  52  ( FIG. 2 ) inside the blower compartment  10 , wherein a heater  62  of the heat kit  52  is directed through a narrow opening  28  in the blower compartment without damaging the heater  62  of the heat kit  52 .  
         [0024]     Further referring to  FIG. 1 , guide  30  is supported by support members  20 ,  22 , such as angle rail members, and may additionally include a tab  46  extending from an end  42  of the guide  30  that is received in a slot  45  formed in a panel  14  of the AHU compartment that is secured to support member  20 . Guide  30  includes a base  32  having opposed sides  34 ,  36 , with retainers  35 ,  37  extending from the respective sides  34 ,  36 . Collectively, retainer  35  and retainer  37  each define a channel  38  with the base  32  to receive a portion of a heat kit  52 , such as a bracket  78  (see  FIGS. 2, 3 ) for guiding the heat kit  52  into an installed position (see  FIG. 8 ) without damaging the heat kit  52 . Moreover, a projection  44  is preferably disposed adjacent to both the end  40  and the channel  38  of guide  30 , as will be further discussed in detail below. Preferably, tab  46  extends from end  42  of the guide  30  for insertion into slot  45  in the panel  14  to secure the guide  30  to the support structure inside the AHU blower compartment. It is also preferable that a tab  48  extends from end  40  at an angle with respect to the base  32  to abut the support structure  20  upon installation of the guide  30  inside the AHU blower compartment  10 . A fastener  50 , such as a screw or bolt, is actuated to secure the guide  30  to the support structure  20 .  
         [0025]     It is appreciated that in  FIG. 1  the guide  30  is shown having a unitary construction including a pair of channels for receiving corresponding structure of the heat kit  52 . However, the guide  30  can be constructed of two or more pieces, and can be any suitable construction that slidably engages the heat kit  52  so that the heat kit  52  is not damaged during installation inside the AHU blower compartment  10 , irrespective the orientation of the heat kit  52 .  
         [0026]     Both the opening  28  and slot  45  formed in the panel  14  of the AHU blower compartment  10 , as well as the aperture for securing tab  48  of guide  30  to the support member  22  if desired, can be formed during manufacture of the AHU blower compartment  10 . A plate (not shown) can then be installed over opening  28  if the AHU as manufactured is not to include the heat kit. Alternately, a template (not shown) provided with each heat kit can be used to locate and subsequently form the opening  28  and slot  45  in panel  14  of the AHU blower compartment  10 .  
         [0027]     Referring to  FIGS. 1-6 , heat kit  52  includes a base  54  having adjacent base portions  56 ,  58  preferably maintained perpendicular to each other for securing respective components  70 ,  68  thereto. An end of base portion  56  includes a retainer  60  for abutting the support structure  20  when the heat kit  52  is in an installed position (see  FIG. 8 ). The retainer  60  includes a gap  61  so that retainer  60  does not interfere with the tab  48  of the guide  30 . Components  70 ,  68  can include any combination of limit switches, control devices, such as relays or sequencers, circuit breakers, or the like required for operation of the heat kit  52 . Components  70 ,  68  are electrically connected by an electrical connection  72 , as required. Further, one of the components  70 ,  68  include a wiring harness  74  and connector  76  to connect with an electrical power source (not shown). Preferably, heater  62  extends substantially perpendicular from base portion  58  so that when the heater  62  is installed in the AHU compartment  10 , heater  62  extends through the opening  28  of the AHU compartment and is in fluid communication with the air provided by the blower  12  for providing heated air to the structure. Heater  62  typically includes a plurality of supports  66  secured to the base portion  58 , the supports  66  supporting electric resistance coils  64  that become heated when electrical current is applied to the coils  64 .  
         [0028]     To secure the heat kit  52  to the guide  30 , a bracket  78  is secured to the bottom surface of the base portion  56  adjacent to the juncture of base portions  56 ,  58 . Bracket  78  includes a base  80  having opposed legs  82  extending substantially perpendicular to the juncture of base portions  56 ,  58 . Each leg  82  has a leg portion  84  extending away from the base  80 , such as perpendicular from the base  80 , and a flange  86  extending from leg portion  84  away from the base  80 . Flanges  86  preferably are substantially parallel with the base portion  56 . The ends of the flanges  86  adjacent to the juncture between the base portions  56 ,  58  each include a chamfer  88  to more easily facilitate the engagement of the flange  86  with the guide  30 . To install the heat kit  52 , the chamfered end  88  of the flanges  86  are directed toward and between the oversized projections  44 , which greatly assists in aligning the flanges  86  with the channels  38  of the guide  30 . The projections  44  may be parallel to each other or non-parallel to each other, such as defining a V-shape, to provide a “funnel effect” to further assist in bringing the flanges  86  into alignment with the channels  38 . Once the flanges  86  are disposed between the projections  44  with each chamfered end  88  of a flange  86  adjacent to a corresponding channel  38 , the orientation of the base portion  56  must only be slightly pivoted about an axis  89  defined by the chamfered ends  88  to sufficiently align the flange  86  with the corresponding channels  38  to permit insertion of the flanges  86  inside the channels  38 . Once the flange  86  insertion begins to occur, the heat kit  52  is properly aligned so that the heater  62  can be directed through the opening  28  until base portion  58  of the heat kit  52  abuts the panel  14  of the AHU compartment, the base portion  58  completely covering and overlapping the opening  28  as shown in  FIG. 8 .  
         [0029]      FIG. 7  shows the heat kit  52  being partially installed after the flanges  86  and the channels  38  have been partially engaged, while  FIG. 8  shows the heat kit  52  in a fully installed position. To secure the heat kit  52  in its installed position, fasteners (not shown) can be installed through either or both of the base portions  56 ,  58  of the base  54  of the heat kit  52  and supporting structure  20 ,  22  or panel  14  of the AHU compartment wall.  
         [0030]     In an alternate construction to bracket  78 , referring to  FIG. 4 , a U-shaped rod  90  having opposed legs  92  separated by a web  94  is secured at a predetermined spacing from the bottom of base portion  56  for engaging guide  30 . Each end of the legs  92  extends through an aperture  98  formed in retainer  60 . Preferably, a standoff  100 , or two or more of standoffs  100 , is interposed between the web  94  and the base portion  56  to secure the web  94 . To install the heat kit  52  in the AHU compartment  10 , the junctures of the legs  92  and web  94  are directed toward and between the oversized projections  44 , which greatly assists in aligning the legs  92  with the channels  38  of the guide  30 . Once the junctures of the legs  92  and web  94  are disposed between the projections  44  with each juncture of the legs  92  and web  94  adjacent to a corresponding channel  38 , the orientation of the base portion  56  must only be slightly pivoted about the web  90  to sufficiently align the legs  92  with the corresponding channels  38  to permit insertion of the legs  92  inside the channels  38 . Once the leg  92  insertions begin to occur, the heat kit  52  is properly aligned so that the heater  62  can be directed through the opening  28  until base portion  58  of the heat kit  52  abuts the panel  14  of the AHU compartment  10 .  
         [0031]     Referring to  FIG. 5 , a pair of rod members  102  is used to guide heat kit  52  inside the AHU compartment  10 . Each rod member  102  includes a substantially straight section  110  that extends to a transition portion  106  having an end  104  that is inserted into an aperture  98  formed in the retainer  60 . Opposite the transition portion  106 , the substantially straight section  110  extends to a transition portion  108  that is secured to the base portion  56  by methods known in the art, including adhesives, welding, or insertion into a recess formed in the base portion  56 . To install the heat kit  52  in the AHU compartment, the junctures of the transition portions  108  and rod members  102  are directed toward and between the oversized projections  44 , which greatly assists in aligning the straight portions  110  with the channels  38  of the guide  30 . Once the junctures of the transition portions  108  and straight portions  110  are disposed between the projections  44  with each juncture of the transition portions  108  and straight portions  110  adjacent to a corresponding channel  38 , the orientation of the base portion  56  must only be slightly pivoted about an axis  111 . Pivoting about axis  111 , which is defined by the juncture of the transition portions  108  and straight portions  110 , sufficiently aligns the straight portions  110  with the corresponding channels  38  to permit insertion of the straight portions  110  inside the channels  38 . Once the straight portion  110  insertions begins to occur, the heat kit  52  is properly aligned so that the heater  62  can be directed through the opening  28  until base portion  58  of the heat kit  52  abuts the panel  14  of the AHU compartment, the base portion  58  completely covering and overlapping the opening  28  as shown in  FIG. 8 .  
         [0032]     Referring to  FIG. 6 , another embodiment of the heat kit  52  includes a pair of opposed legs  112  extending from the bottom of base portion  56 . Each leg  112  includes a leg portion  114  that extends away from the base portion  56 , and flange  116  that extends from the leg portion  114  away from base portion  56 . The legs  112  provide a unitary base  54  construction. Each flange  116  is configured to engage a corresponding channel  38  to secure the heat kit  52  to the guide  30 , the flanges  116  preferably including a chamfer  118  adjacent the juncture of base portions  56 ,  58  to further facilitate engagement with the channel  38  in a manner previously discussed.  
         [0033]     Those skilled in the art can appreciate that although the guide  30  is shown as a component that is installed in the AHU compartment, the guide can be incorporated into the existing support structure  20 ,  22  or transverse members  24 ,  26 , if desired. Further, although the guide  30  as shown requires the heat kit to be inserted inside the AHU compartment, the guide can be extended outside the AHU compartment to permit the heat kit to engage the guide exterior of the AHU compartment, the guide being usable to guide the heat kit to its installed position. The extended portion of the guide could be removable if desired.  
         [0034]     It is to be understood that base  54  and base portion  56  can have unequal widths. Further, while retainers  35 ,  37  are shown to define channels  38  on guide  30  that face each other (i.e.,  FIG. 1 ), as shown in  FIG. 9 , the channel arrangement can also face away from each other. For example, guide  130  includes a base  132  having opposed legs  134 . Each leg  134  has a leg portion  136  extending away from the base  132 , such as perpendicular to the base  132  and a flange  138  extending from leg portion  136  away from base  132 . Flanges  138  preferably are substantially parallel with the base  132 . Bracket  178 , which is otherwise similar to bracket  78 , includes flanges  186  that differ from flanges  86  in that flanges  186  extend toward each other. Collectively, each flange  186 , leg portion  84  and base  80  defines a channel  188 . Each flange  138  of the bracket  130  slidably engages a corresponding channel  188  to secure the base portion  56  of the heat kit  52  to the guide  130 .  
         [0035]     In a further alternate guide construction as shown in  FIG. 10 , guide  230  includes a base  232  having a leg  234  extending away from the base  232 . Leg  234  terminates at a cap  236  having flange portions  238  extending away from leg  234 . Each flange portion  238  slidably engages a corresponding channel  188  to secure the base portion  56  of the heat kit  52  to the guide  230 .  
         [0036]     While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.