Patent Publication Number: US-10775072-B2

Title: Cover channel, cover frame, insulating panel, air handling unit and method for manufacturing a cover channel

Description:
The present invention concerns a cover channel, a cover frame comprising such a cover channel, an insulating panel comprising such a cover frame and an air handling unit comprising such an insulating panel, and a method for manufacturing such a cover channel. 
     It is known to implement air handling units on buildings, especially office buildings or supermarkets, for treating the air contained inside the building. Such handling units usually have inlet and outlet openings, for the air to be circulated through the unit, and a plurality of components, each relative to a function for treating the air, such as circulating, filtering, depolluting, humidifying, drying, heating, cooling, or the like. These components are enclosed inside a structural frame, supporting a housing made of flat insulating panels, forming a protective thermal barrier of the air handling unit. Each panel comprises an insulating core material, for example a glass-wool, interposed between two metallic walls. At least some of the panels of the unit are removable, or provided with handles, hinges or the like, so that they may be removed or opened for maintenance of the internal components contained within the unit. Usually, the panels are secured to the frame and/or to each other by means of fasteners such as screws, rivets or the like. 
     WO-A1-01/50068 discloses a one-piece extruded plastic channel configured to support two planar panels having a predetermined thickness in parallel spaced relationship, by receiving free edges of the panels therein. The channel includes an elongated body of U-shaped section, which includes a flat intermediate section and a pair of rigid outer walls, one of which extends from each of the lateral edges of the intermediate section. The U-shaped body further includes a pair of flexible inner walls, each of which extends from a junction with the intermediate section at a position adjacent to and spaced laterally inwardly from one of the outer walls. The channel is configured to be mounted on both planar panels, by insertion of the respective edges of the panels in between adjacent inner and outer walls. 
     However the known handling units are frequently subject to leakage of air, heat and humidity, especially at the outline of the panels or the inlet and outlet openings, despite the presence of plastic channels. In some cases leaking fluid may reach and harm the insulating core of the panels. 
     The aim of the invention is to provide a cover channel which may efficiently prevent fluid leakage at an edge of an insulating panel while being especially easy to mount onto said insulating panel. 
     To this end, the invention concerns a cover channel according to claim  1 . 
     Thanks to the invention, the sealing gasket is brought in tight contact with at least one of the rim portions when the cover channel is mounted onto the edge, so that fluid leakage is prevented at the edge of the insulating panel, while the cover channel is easy to mount thereto. 
     Further optional and advantageous aspects of the invention are defined in claims  2  to  6 . 
     The invention further relates to a cover frame according to claim  7 . 
     Further optional and advantageous aspects of the invention are defined in claims  8  to  11 . 
     The invention further relates to an insulating panel, according to claim  12 , to an air handling unit, according to claim  13 , and to a method for manufacturing according to claim  14 . 
    
    
     
       The invention will now be explained in reference to the annexed drawings, as an illustrative example. In the annexed drawings: 
         FIG. 1  is a perspective view of an air handling unit according to the invention; 
         FIG. 2  is a perspective view of an insulating panel of the air handling unit of  FIG. 1 , provided with a cover frame according to the invention, including cover channels and cover corners; 
         FIG. 3  is a perspective view of one of the cover channels of  FIG. 2 ; 
         FIG. 4  is a partial cross-section of one of the cover channels mounted on the insulating panel of  FIG. 2 ; 
         FIGS. 5 and 6  are two different perspective views of one of the cover corners of  FIG. 2 . 
     
    
    
       FIG. 1  shows an air handling unit  1  which comprises structural frame including horizontal beams  2  and vertical beams  3 . These beams  2  and  3  support a housing made of flat thermal insulating panels, of substantially rectangular shape. Some of these panels are omitted from  FIG. 1  for making the inside of the housing visible. Some other panels  4 A and  4 B constitute inlet panels  4 A and  4 B. Some further panels constitute outlet panels  4 C and  4 D. Further panels constitute horizontal roof panels  4 E and horizontal floor panels  4 F. 
     The air handling unit  1  comprises two levels, namely a first level  5  and a second level  7  superposed over said first level  5 . Level  7  is delimited at its ends by panels  4 A and  4 B, laterally by successive panels not shown in  FIG. 1 , at the top by roof panels  4 E and at the bottom by floor panels  4 F. Similarly, level  7  is delimited at its ends by panel  4 C and  4 D, the panel  4 D being positioned in the same plane as panel  4 A, while panel  4 C is positioned in a plane parallel to the plane of panel  4 B, at a distance of panel  4 C. The distance between panels  4 B and  4 C covered by two roof panels  4 E covering the top of level  5  between panel  4 B and panel  4 C. Successive lateral panels, not shown on  FIG. 1 , cover level  5  laterally, while the bottom of level  5  is delimited by floor panels  4 F. 
     The air handling unit  1  includes several components, some of which are illustrated in  FIG. 1 . Among these components, this air handling unit  1  comprises a fan motor assembly  9  enclosed inside the housing at level  5 , at the vicinity of panel  4 C. The air handling unit  1  comprises a further fan motor assembly  11 , enclosed at level  7  between panels  4 A and  4 B. The air handling unit  1  also has an air heat exchanger  13  provided across levels  5  and  7 , between panel  4 A and the fan motor assembly  114 , and between panel  4 D and the fan motor assembly  9 . A first air flow A 1  is circulated by means of fan motor assembly  9 , the air flow A 1  being admitted through inlet panel  4 A, then passing through the exchanger  13  and through a thermodynamic machine  15  provided between the exchanger  13  and the fan motor assembly  9  at level  5 . The air flow A 1  then passes through the fan motor assembly  9  and exits the air handling unit  1  through the outlet panel  4 C. The outlet panel  4 C is advantageously connected to an air duct of a building, not shown, at the top of which the air handling unit  1  is installed. Alternatively, the air handling unit  1  may be installed in a basement of such a building, or in any other suitable part of the building. 
     The second air flow A 2  is admitted through inlet panel  4 B, and passes through the fan motor assembly  11 , then the exchanger  13 , where thermal energy is exchanged between the flows A 1  and A 2 . The flow A 2  is then directed to level  5  and exits the air handling unit  1  through outlet panel  4 D. The inlet panel  4 B is advantageously connected to an air duct of the building. 
     The air handling unit  1  is also provided with air filters  17  and  19  enclosed in the housing at the vicinity of inlet panels  4 A and  4 B. 
     As it is illustrated in  FIG. 4 , each of the insulating panels  4 A to  4 F has two substantially parallel outer walls  21  and  23  made of a substantially rigid material such as aluminum alloy or plastic material. The panels  4 A to  4 F further comprise a thermal insulating material layer  25  interposed between said outer walls  21  and  23 , such as glass-wool, insulating foam, or any other suitable material, to convey insulating properties to said panels  4 A to  4 F and limit heat transfer from one side of the panel to the other side. Thus, the panels  4 A to  4 F constitute a thermal barrier enclosing the components of the air handling unit  1 , so that heat losses of the air flows A 1  and A 2  through the air handling unit  1  are limited. In addition, the panels  4 A to  4 F are secured to the beams  2  and  3  of the structural frame for forming a substantially airtight housing guiding the air flows A 1  and A 2 . 
     The panels  4 E and  4 F, as well as the lateral panels, are closed, while panels  4 A,  4 B,  4 C and  4 D are each provided with an opening  27 , as illustrated for panel  4 A in  FIG. 2 . Depending on which panel, the opening  27  may be used as an inlet or an outlet for one of the flows A 1  or A 2 , through the concerned insulating panels  4 A,  4 B,  4 C or  4 D. The opening  27  may be connected to an air duct, provided with shutters, and/or any other component related to air admission or extraction. For each of said panel, the opening  27  defines a rectangular edge  29 , defining the outline of the opening  27 . Along this edge  29 , each of the outer walls  21  and  23  define a rim portion numbered  31  and  33 , respectively, of substantially rectangular shape as depicted in  FIG. 3 . As the shape of the opening  27  is rectangular, the edge  29 , and the rim portions  31  and  33 , comprise four edge corners  35  linked by four longitudinal portions  37 . 
     The opening  27  is provided with a cover frame  39  covering the edge  29  of the opening  27 . The cover frame  39  comprises four cover channels  41 , each covering one of the longitudinal portions  37  of the edge  29 . 
     The cover channel  41  comprises an elongated body  43 , visible in particular on  FIGS. 3 and 4 , having with two longitudinal ends  44 . This elongated body  43  has a cross-section, visible on  FIG. 4 , which is preferably constant from one end  44  to the other. The elongated body  43  is preferably a profile obtained by extruding a substantially rigid material such as an aluminum alloy or a plastic material from an end  44  to the other. Plastic material is preferred, since it has thermal insulating properties. 
     The elongated body  43  of the cover channel  41  comprises a cover portion  45  forming a substantially flat board for covering the open edge  29  and avoiding the insulating material  25  to flee through the longitudinal portions  37 . The cover portion  45  extends in a plane perpendicular to the walls  21  and  23  when the cover channel  41  is mounted onto the longitudinal portion  37 . The cover portion  45  is provided with reinforcing ribs  47  extending along the elongated body  43 , and protruding towards the insulating material  25  when the cover channel  41  is mounted onto the edge  29 . A face  49  of the cover portion  45  opposite to the reinforcing ribs  47  is preferably substantially flat. 
     The elongated body  43  further comprises two outer portions  51 , protruding respectively from lateral edges of the cover portion  45 , in a substantially perpendicular direction relative to the cover portion  45 , in the same direction than the ribs  47 . Thus, the cross-section of the elongated body  43  is U-shaped. The outer portions  51  form two lateral wings of the elongated body  43  configured to recover the rim portions  31  and  33  when the cover channel  41  is mounted onto the edge  29 . Thus, the edge  29  is continuously recovered by the elongated body  43 , from the rim portion  31  to the rim portion  33 . 
     The elongated body  43  also comprises two clamping portions  53 , each protruding from the cover portion alongside one of the outer portions  51 . The clamping portions  53  are arranged between the outer portions  51  for covering inside faces of the rim portions  31  and  33 , respectively. The clamping portions  53  form two longitudinal wings extending substantially parallel to the outer portions  51  and perpendicular to the cover portion  45 . Each of the clamping portions  53  defines a clamping gap  55  with its adjacent outer portion  51 . The two clamping gaps  55  each form a rail extending longitudinally and shaped to accommodate respective rim portions  31  and  33 , all along one longitudinal portion  37  of the edge  29 . Each of the clamping gaps  55  is sufficiently narrow so that each of the rim portions  31  and  33  is slightly squeezed between adjacent clamping portion  53  and outer portion  51 , by slight elastic deformation of the material of the elongated body  43 . Thus, the cover channel  41  is retained onto the edge  29 . 
     The elongated body  43  comprises retaining ribs  57  and  58  protruding within the clamping gaps  55  for better retaining. In this example, as visible on  FIG. 4 , each of the outer portions  51  is provided with three retaining ribs  57  protruding towards the adjacent clamping portion  53 . Three retaining ribs  58  are also provided on each clamping portion  53 , and protrude towards the adjacent outer portion  51 , at staggered locations relative to the ribs  57  of the outer portion  51 . The retaining ribs  57  and  58  extend all along the elongated body  43 . 
     For an easier clamping of the cover channel  41  onto the longitudinal portion  37  of the edge  29 , the clamping portions  53  comprise an intermediate part  59  parallel to the adjacent outer portion  51  and an end part  61  of narrower thickness than the intermediate part  59 . The end part  61  extends from the intermediate part  59  and is inclined away from the adjacent outer portion  51 . In other words, each clamping gap  55  is sufficiently narrow at the base for an appropriate clamping of the rim portions  31  and  33 , and slightly flaring at the open end, as depicted on  FIG. 4 . In addition, the clamping portions  53  are shorter than the outer portion  51  for easier mounting of the cover channel  41  onto the edge  29 . 
     The cover channel  41  further comprises two sealing gaskets  63  provided along the elongated body  43 , at the base of the clamping gaps  55 . Each sealing gasket  63  rests against the cover portion  45 , between adjacent outer portion  51  and clamping portion  53 . Each sealing gasket  63  is provided with a longitudinal V-shaped groove  65  extending along the elongated body  43 . Each of the grooves  65  is open towards the opening of the clamping gap  65  within which said groove  65  is provided, in the direction opposite to the cover portion  45 . Each of the grooves  65  is configured to receive one of the rim portion  31  and  33  so that, when the cover channel  41  is clamped onto the edge  29 , the sealing gaskets  63  are compressed between the rim portions  31  and  33  and the cover portion  45 , thus ensuring tightness and protection of the inside of the concerned panel  4 A,  4 B,  4 C or  4 D. 
     The sealing gaskets  63  are made of a flexible material, such as an elastomer or any other suitable material, which can be extruded. Preferably, the elongated body  43  and the sealing gaskets  63  are coextruded together, so that the cover channel  41  is easy to manufacture. 
     The cover frame  39  further comprises four cover corners  67 , configured to be mounted onto the edge corners  35  of the opening  27 , at the ends  44  of the cover channels  41 , as visible on  FIG. 2 . One of these cover corners  67  is depicted independently on  FIGS. 5 and 6 . The cover corner  67  is made of an elastic material, preferably an elastomer, so as to be mounted onto the elongated body  43 , made of a more rigid material than elastomer, by elastic deformation of the cover corner  67 . 
     The cover corner  67  comprises a central corner part  69 , provided with two opposite overlaying portions  71  extending along planes angled with an angle β. Each of the overlaying portions  71  is configured for partially overlaying one cover portion  45  of a respective cover channel  41 . As visible on  FIG. 2 , each overlaying portion  71  covers one of the ends  44  of a cover channel  41 , when the cover corner  67  is mounted thereto. 
     The cover corner  67  further has an anchor  73 , protruding from a ridge  75  formed at the intersection of the overlaying portions  71 , opposite the angle β. The anchor  73  is provided with two groups of successive fins  77 , for example three successive fins  77 , directed perpendicular to the ridge  75 , the fins  77  of the two groups being oriented away from each other. The cover corner  67  may be mounted onto the end  44  by anchoring the fins  77  of the anchor  73  to the ends  44 , the anchor being caught between the ends  44  of two adjacent cover channels  41 . 
     As depicted on  FIGS. 3 and 4 , in the present example, the angle β equals 110° when the cover corner  67  is not mounted, in other words not deformed. When mounted onto the cover channels  41  by means of the anchor  73 , the overlaying portions  71  are elastically deformed and pressed in an airtight manner onto the ends  44  of the two adjacent cover channels  41 , so that that angle β becomes equal to approximately 90°. Alternatively, the angle β can be chosen to be equal to a value of 95° or more when the cover corner  67  is not deformed. 
     The cover corner  67  is also provided with two planar cover wings  79 , substantially parallel to each other when the cover corner  67  is not deformed. Each of the cover wings  79  protrudes from one edge of the corner part  69  in a similar direction, opposite the angle β. Thus, the anchor  73  is formed between the cover wings  79 . As depicted on  FIG. 2 , the cover wings  79  are configured to recover the outer portions  51  of two adjacent cover channels  41 , at the ends  44  thereof, and to recover one of the edge corners  35 . In particular, each cover wing  79  has two overlaying portions  81 , oriented inwards, for partially overlaying one of the outer portions  51  at on of the ends  44 , when the cover corner  67  is mounted thereto. Facing overlaying portions  81  of the two cover wings  79  are linked by the overlaying portion  71  of the corner part  69  for forming a continuous U-shaped overlaying portion for recovering the end  44  of one of the cover channels  41 . The two opposite overlaying portions  81  of each cover wing  79  are linked by a central corner portion  83 , connected to an end of the anchor  73 . The central corner portion  83  is configured to recover and be in tight contact with the rim portion  31  or  33  of the one of the outer walls  21  or  23 . 
     Each of the cover wings  79  comprises a hook  85 , or any other suitable fastening means, for being secured to one of the outer walls. Each hook  85  protrudes from the central corner part  83  of the concerned cover wing  79 , in a direction oriented inwardly. The hooks  85  are adapted for being anchored to corresponding holes, not visible on the figures, of the outer wall  21  and  23 . 
     Optionally, a through hole  80  is provided in each cover wing  79 , for centering and/or mounting a component onto the opening  27 , such as a damper, not illustrated. 
     The cover corner  67  being elastically deformable, the cover wings  79  can be elastically deformed away from each other for allowing positioning of the cover corner  67  onto the ends  44 . Once the anchor  73  is forcibly inserted and retained between the ends  44  of the two adjacent cover channels  41 , the cover wings  79  may be folded back onto the respective outer walls  21  and  23 , and the hooks  85  secured thereto. The hooks are preferably configured to ensure tight contact of the cover wings  79  onto said outer walls  21  and  23  and onto the outer portions  51  of the adjacent cover channels  41 . 
     Thus, the cover frame  39  constitutes tight protection means of the edge  29  of the opening  27 . 
     In a non-illustrated alternative, the cover channels  41  may be secured to a peripheral or lateral edge of any insulating panel similar to the panels  4 A to  4 F disclosed hereinabove. 
     The aforementioned embodiments and features of the invention may be combined for generating further embodiments of the invention.