Patent Publication Number: US-9851114-B2

Title: HVAC system with multipurpose cabinet for auxiliary heat transfer components

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not applicable. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     REFERENCE TO A MICROFICHE APPENDIX 
     Not applicable. 
     BACKGROUND 
     Heating, ventilation, and air conditioning systems (HVAC systems) sometimes comprise an auxiliary heat transfer component (AHTC). An AHTC may be configured to provide a heating effect, a cooling effect, or both. In some embodiments, an AHTC may be disposed within a so-called “air handling unit” (hereinafter referred to as an “AHU”) that may comprise a primary heat exchanger (hereinafter referred to as a PHE) and one or more fans and/or blowers configured to selectively force air through the AHTC and/or the PHE of an HVAC system for delivery into a building or space to be conditioned by the HVAC system. 
     SUMMARY OF THE DISCLOSURE 
     In some embodiments of the disclosure, an HVAC system is provided that comprises an airflow path, a primary heat exchanger disposed along the airflow path, wherein the airflow path at least partially passes through the primary heat exchanger, and a multipurpose cabinet selectively configurable between at least a first configuration for housing a first type of auxiliary heat transfer component and a second configuration for housing a second type of auxiliary heat transfer component, wherein the airflow path at least partially passes through the multipurpose cabinet. 
     In other embodiments of the disclosure, a multipurpose cabinet for an HVAC system is provided that comprises a plurality of walls, at least one backing plate, and a front cover. In some embodiments, the plurality of walls and the front cover are configurable to be joined together to at least partially envelope a space the multipurpose cabinet comprises a first configuration for housing at least a portion of a first type of auxiliary heat exchange component within the space and wherein the multipurpose cabinet comprises a second configuration for, to the exclusion of the first type of auxiliary heat exchange component, housing at least a portion of a second type of auxiliary heat exchange component within the space. 
     In still other embodiments of the disclosure, an air handling unit for an HVAC system is provided that comprises a blower cabinet, a blower at least partially carried within the blower cabinet, a primary heat exchanger cabinet, a primary heat exchanger at least partially carried within the primary heat exchanger cabinet, and a multipurpose cabinet comprising a first configuration for housing at least a portion of a first type of auxiliary heat exchange component within the multipurpose cabinet and a second configuration for, to the exclusion of the first type of auxiliary heat exchange component, housing at least a portion of a second type of auxiliary heat exchange component within the multipurpose cabinet. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of the present disclosure and the advantages thereof, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts. 
         FIG. 1  is a schematic view of an HVAC system comprising a multipurpose cabinet for an AHTC according to an embodiment of the disclosure; 
         FIG. 2  is a schematic view of an HVAC system comprising a multipurpose cabinet for an AHTC according to another embodiment of the disclosure; 
         FIG. 3  is a schematic view of an HVAC system comprising a multipurpose cabinet for an AHTC according to another embodiment of the disclosure; 
         FIG. 4  is a schematic view of an HVAC system comprising a multipurpose cabinet for an AHTC according to another embodiment of the disclosure; 
         FIG. 5  is a schematic view of an HVAC system comprising a multipurpose cabinet for an AHTC according to another embodiment of the disclosure; 
         FIG. 6  is a schematic view of an HVAC system comprising a multipurpose cabinet for an AHTC according to another embodiment of the disclosure; 
         FIG. 7  is a schematic view of an HVAC system comprising a multipurpose cabinet for an AHTC according to another embodiment of the disclosure; 
         FIG. 8  is a schematic view of an HVAC system comprising a multipurpose cabinet for an AHTC according to another embodiment of the disclosure; 
         FIG. 9  is a schematic view of an HVAC system comprising a multipurpose cabinet for an AHTC according to another embodiment of the disclosure; 
         FIG. 10  is a schematic view of an HVAC system comprising a multipurpose cabinet for an AHTC according to another embodiment of the disclosure; 
         FIG. 11  is a schematic view of an HVAC system comprising a multipurpose cabinet in a first configuration for a first type of AHTC according to another embodiment of the disclosure; 
         FIG. 12  is a schematic view of the HVAC system of  FIG. 11  with the multipurpose cabinet in a second configuration for a second type of AHTC; 
         FIG. 13  is a schematic view of an HVAC system comprising a multipurpose cabinet for an AHTC according to another embodiment of the disclosure; and 
         FIG. 14  is a schematic view of an HVAC system comprising a multipurpose cabinet for an AHTC according to another embodiment of the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     HVAC systems may comprise an auxiliary heat transfer component (AHTC) in addition to a primary heat exchanger (PHE). In some embodiments, the AHTC may be configured for use in the case of failure of a PHE. In other embodiments, an AHTC may be configured for use in concert with a PHE to provide the HVAC system with supplemental heat transfer capacity. For example, when a heating PHE, such as a furnace, is used in combination with a heating AHTC, the total heating capacity of the HVAC system may comprise at least the sum of the heating capacities of the heating AHTC and the heating PHE. Similarly, when a cooling PHE, such as an evaporator coil, is used in combination with a cooling AHTC, the total cooling capacity of the HVAC system may comprise at least the sum of the cooling capacities of the cooling AHTC and the cooling PHE. 
     In other embodiments of an HVAC system, an AHTC may be configured for simultaneous use with a PHE to provide the HVAC system an improved ability to more accurately deliver a desired rate of heat transfer and/or to deliver air to a conditioned space at a selected temperature with greater control. For example, because a cooling PHE may cool air to a temperature below a desired delivery temperature, a heating AHTC may be used to warm the air so that a selected delivery temperature may be achieved. Similarly, because a heating PHE may heat air to a temperature above a desired delivery temperature, a cooling AHTC may be used to cool the air so that a selected delivery temperature may be achieved. 
     In some embodiments, a single PHE may selectively provide heating or cooling, as may be the case of a heat exchanger of a so-called heat pump system. Similarly, an AHTC may selectively provide heating or cooling, as may be the case of a hydronic heat exchanger (HHE) which primarily uses heated or cooled water as a heat transfer medium. In other embodiments, an AHTC may comprise one or more resistive electrical heat elements (REHE) that are configured to generate heat by converting electrical energy into heat energy. 
     While some embodiments of an REHE may generate temperatures of about 160° F. or above, an HHE may generate temperatures that typically do not exceed 180° F. Further, while an REHE requires a supply of electrical energy and associated electrical switching components, an HHE, in some cases, may require only a water input line and a water output line. As described above, the operating conditions and structural requirements of various types of AHTCs may be different. Those differences may lead to undesirably high manufacturing costs and/or inefficiencies related to manufacturing multiple types of AHTC enclosure models and/or AHTC cabinet models suitable for housing the various types of AHTCs. 
     There is a need for an HVAC system comprising a cabinet that is suitable for use with multiple types of AHTCs. Accordingly, the present disclosure provides systems and methods for safely and effectively housing various types of AHTCs within a so-called “multipurpose cabinet” for AHTCs. In some embodiments, a multipurpose cabinet may comprise materials and other features to safely house an REHE and its required electrical connections while also being configured to alternatively safely house an HHE and its required water input line and water output line, the multipurpose cabinet being generally configured to house one type of AHTC at any one time. In some embodiments, the multipurpose cabinet may comprise features provided to allow easy insertion and/or removal of a plurality of types of AHTCs. For example, in some embodiments, a multipurpose cabinet may comprise features well suited for allowing easy insertion, removal, and/or housing an REHE when the multipurpose cabinet is arranged in a first configuration and alternatively well suited for allowing easy insertion, removal, and/or housing an HHE when the multipurpose cabinet is arranged in a second configuration. In some embodiments, the multipurpose cabinet may be formed integrally with an AHU. In some embodiments, the multipurpose cabinet may be removable from an AHU in a modular and/or quick-connect manner. In some embodiments, the multipurpose cabinet may be configured for installation remote from an AHU and may be configured for insertion along an airflow path of an HVAC system that is downstream or upstream of an AHU. 
       FIG. 1  shows an HVAC system  100  according to an embodiment of this disclosure. The HVAC system  100  comprises an AHU (sometimes referred to as an indoor unit)  102  and an outdoor unit (sometimes referred to as a condensing unit)  104 . In this embodiment, the AHU  102  may be conceptualized as comprising a plurality of cabinet portions. Particularly, the AHU  102  may be conceptualized as comprising a blower cabinet  106 , a primary heat exchanger cabinet  108 , and a multipurpose cabinet  110 . In some embodiments, the cabinet portions of the AHU  102  may be formed integrally as a single unit. In other embodiments, one or more of the cabinet portions of the AHU  102  may be formed in a modular manner so that the cabinet portions may selectively be joined to each other and/or removed from each other in a so-called quick-connect manner or other convenient manner. In this embodiment, the blower cabinet  106  is configured to house a blower  112 , the primary heat exchanger cabinet  108  is configured to house a PHE  114 , and the multipurpose cabinet  110  is configurable to house at least two different types of AHTCs. In some embodiments, the blower  112  may comprise a centrifugal fan, a mixed-flow type fan, a radial fan, and/or any other suitable air moving device. In some embodiments, the PHE  114  may comprise a fin and tube type refrigerant heat exchanger and may be referred to as a so-called evaporator coil. In some embodiments, the multipurpose cabinet  110  may be selectively configurable to house an REHE and a HHE, in most embodiments only one at a time. For example, the multipurpose cabinet is shown in  FIG. 1  as being configured in a first configuration to house an AHTC  116  comprising a HHE. The same multipurpose cabinet  110  shown in  FIG. 1  may selectively be configured to alternatively house an AHTC comprising an REHE. 
     The outdoor unit  104  comprises a compressor  118 , an outdoor heat exchanger (sometimes referred to as a condenser coil)  120 , and an outdoor fan  122 . In operation of the compressor  118  to provide a cooling effect, refrigerant may be compressed by the compressor  118  and pumped through a discharge line  124  to the outdoor heat exchanger  120 . The outdoor fan  122  may be operated to cool the refrigerant passing through the outdoor heat exchanger  120  and the refrigerant may be passed through a liquid line  126  to the primary heat exchanger  114 . Prior to reaching the PHE  114 , the refrigerant may be passed through a refrigerant expansion device  128  which results in a cooling of the refrigerant. The refrigerant may be returned to the compressor  118  through a suction line  130 . The cooled refrigerant cools the PHE  114  and the blower  112  may be operated to move air along an airflow path  132 . The airflow path  132 , in some embodiments, at least partially originates and at least partially terminates in a space  134  conditioned by the HVAC system  100 . Most generally, the airflow path  132  may be configured to pass through the AHU  102  so that the air following the airflow path  132  may be selectively conditioned by the PHE  114  and/or the AHTC  116 . Of course, in alternative embodiments, such as, but not limited to, heat pump HVAC systems, an HVAC system  100  may be configured differently from the manner shown in  FIG. 1  in order to provide heating and/or cooling of air delivered to the space  134 . 
     In some embodiments, the HVAC system  100  may further comprise a water temperature adjustment device  136 . The water temperature adjustment device  136  may comprise a boiler, a water chiller refrigeration system, and/or any other suitable component for selectively adjusting the temperature of water. In some embodiments, the temperature of water may be adjusted by the water temperature adjustment device  136  and the water may thereafter be forced by a pump  138  from the water temperature adjustment device  136  to the AHTC  116  through an inlet line  140 . During operation of the blower  112 , air may interact with the AHTC  116  in a manner that results in an adjustment of the air temperature prior to delivering the air to the space  134 . In some embodiments, water may be returned to the water temperature adjustment device  136  via an outlet line  142 . 
     It will be appreciated that in cases where the multipurpose cabinet  110  may be configured in a second configuration to house an AHTC  116  comprising an REHE, the HVAC system  100  may not comprise one or more of the above-described water temperature adjustment device  136 , pump  138 , inlet line  140 , and outlet line  142 . Instead, the HVAC system may further comprise electrical switches and electrical power supply wires routed to the AHTC  116  to selectively power the REHE. 
     The AHU  102  is referred to as a so-called blow-through AHU  102  because the blower  112  may be located upstream along the airflow path  132  relative to the PHE  114 . In this embodiment, the multipurpose cabinet  110  is located adjacent the primary heat exchanger cabinet  108  and downstream relative to both the primary heat exchanger cabinet  108  and the blower cabinet  106 . 
     Referring now to  FIG. 2 , an HVAC system  100  is shown in an alternative configuration. In this embodiment, the AHU  102  may be referred to as a so-called blow-through AHU  102  because the blower  112  is located upstream along the airflow path  132  relative to the PHE  114 . In this embodiment, the multipurpose cabinet  110  is located adjacent the blower cabinet  106  and upstream relative to both the primary heat exchanger cabinet  108  and the blower cabinet  106 . 
     Referring now to  FIG. 3 , an HVAC system  100  is shown in an alternative configuration. In this embodiment, the AHU  102  may be referred to as a so-called blow-through AHU  102  because the blower  112  is located upstream along the airflow path  132  relative to the PHE  114 . In this embodiment, the multipurpose cabinet  110  is located between the blower cabinet  106  and the primary heat exchanger cabinet  108 . The multipurpose cabinet  110  is located downstream relative to the blower cabinet  106  and upstream relative to the primary heat exchanger cabinet  108 . 
     Referring now to  FIG. 4 , an HVAC system  100  is shown in an alternative configuration. The HVAC system  100  of  FIG. 4  may be configured substantially the same as the HVAC system of  FIG. 1  except that the multipurpose cabinet  110  is not integral with the AHU  102 . Instead, the multipurpose cabinet  110  is remote from the AHU  102  and is located downstream relative to the AHU  102 . 
     Referring now to  FIG. 5 , an HVAC system  100  is shown in an alternative configuration. The HVAC system  100  of  FIG. 4  may be configured substantially the same as the HVAC system of  FIG. 2  except that the multipurpose cabinet  110  is not integral with the AHU  102 . Instead, the multipurpose cabinet  110  is remote from the AHU  102  and is located upstream relative to the AHU  102 . 
     Referring now to  FIG. 6 , an HVAC system  100  is shown in an alternative configuration. In this embodiment, the AHU  102  may be referred to as a so-called draw-through AHU  102  because the blower  112  is located downstream along the airflow path  132  relative to the primary heat exchanger cabinet  108 . In this embodiment, the multipurpose cabinet  110  is located adjacent primary heat exchanger cabinet  108  and upstream relative to both the primary heat exchanger cabinet  108  and the blower cabinet  106 . 
     Referring now to  FIG. 7 , an HVAC system  100  is shown in an alternative configuration. In this embodiment, the AHU  102  may be referred to as a so-called draw-through AHU  102  because the blower  112  is located downstream along the airflow path  132  relative to the primary heat exchanger cabinet  108 . In this embodiment, the multipurpose cabinet  100  is located adjacent the blower cabinet  106  and downstream relative to both the blower cabinet  106  and the primary heat exchanger cabinet  108 . 
     Referring now to  FIG. 8 , an HVAC system  100  is shown in an alternative configuration. In this embodiment, the AHU  102  may be referred to as a so-called draw-through AHU  102  because the blower  112  is located downstream along the airflow path  132  relative to the primary heat exchanger cabinet  108 . In this embodiment, the multipurpose cabinet  110  is located between the blower cabinet  106  and the primary heat exchanger cabinet  108 . The multipurpose cabinet  110  is located downstream relative to the primary heat exchanger cabinet  108  and upstream relative to the blower cabinet  106 . 
     Referring now to  FIG. 9 , an HVAC system  100  is shown in an alternative configuration. The HVAC system  100  of  FIG. 9  may be configured substantially the same as the HVAC system of  FIG. 7  except that the multipurpose cabinet  110  is not integral with the AHU  102 . Instead, the multipurpose cabinet  110  is remote from the AHU  102  and is located downstream relative to the AHU  102 . 
     Referring now to  FIG. 10 , an HVAC system  100  is shown in an alternative configuration. The HVAC system  100  of  FIG. 10  may be configured substantially the same as the HVAC system of  FIG. 6  except that the multipurpose cabinet  110  is not integral with the AHU  102 . Instead, the multipurpose cabinet  110  is remote from the AHU  102  and is located upstream relative to the AHU  102 . 
     Referring now to  FIG. 11 , an exploded view of a multipurpose cabinet  110  configured in a first configuration for housing an AHTC  116  comprising an HHE  144  is shown. In some embodiments, the multipurpose cabinet  110  may generally comprise a rear wall  146 , a left wall  148 , a right wall  150 , a top crossbar  152 , and a removable front cover  154 . As configured for housing the AHTC  116  comprising the HHE  144 , the multipurpose cabinet  110  may further comprise an HHE backing plate  156  that may be offset from the rear wall  146  and extends between the left wall  148  and the right wall  150 . The HHE backing plate  156  may be configured to receive and selectively spatially constrain a rear portion of the HHE  144  when the HHE  144  is inserted into the multipurpose cabinet  110 . The HHE  144  may be inserted and/or removed from the multipurpose cabinet  110  using a forward and/or rearward sliding motion. In some embodiments, the multipurpose cabinet  110  may comprise one or more shelves  158  formed in and/or carried on a forward portion of the left wall  148  and/or on a forward portion of the right wall  150 . The shelves  158  may be sized and shaped to receive a complementary shaped portion of an AHTC front mounting bracket  160 . 
     The AHTC  116  comprising the HHE  144  may be installed into the multipurpose cabinet  110  by sliding the AHTC  116  into the multipurpose cabinet until a rear portion of the AHTC  116  engages and/or is spatially constrained by the HHE backing plate  156  and the AHTC front mounting bracket  160  engages and/or is spatially constrained by the one or more shelves  158 . After such insertion, the water inlet line  140  and water outlet line  142  may be passed through access aperture  164  of the front cover  154  and the lines  140 ,  142  may be joined to the HHE. Additionally, electrical wires and/or conduit may be passed through holes  162  of the multipurpose cabinet  110 . Depending on the orientation of the multipurpose cabinet  110  relative to its surroundings, the holes  162  of the left wall  148 , the right wall  150 , or the top crossbar  152  may be used to accept the electrical wires and/or conduit therethrough. After the inlet line  140  and the outlet line  142  are connected as described above, the front cover  154  may be assembled to the left wall  148  and the right wall  150 . 
     Referring now to  FIG. 12 , an exploded view of the multipurpose cabinet  110  configured in a second configuration for housing an AHTC  116  comprising an REHE  166  is shown. In this embodiment, the multipurpose cabinet  110  may be substantially similar to the configuration shown in  FIG. 11 . However, as configured in the second configuration for receiving an REHE  166 , the multipurpose cabinet  110  may not comprise the HHE backing plate  156 , but rather, may comprise a REHE backing plate  168  that may be shaped and sized complementary to a back portion of the REHE  166 . Also, the REHE backing plate  168  may be located a different offset distance from the rear wall  146  in order to accommodate any difference in depth between the HHE  144  and the REHE  166 . In some embodiments, the HHE backing plate  156  and the REHE  168  backing plate may be formed as a single backing plate that may be selectively installed in at least one of a different location and a different orientation as needed to selectively accommodate the HHE  144  or the REHE  166 . 
     In some embodiments, the AHTC  116  comprising the REHE  166  may be installed into the multipurpose cabinet  110  by sliding the AHTC  116  into the multipurpose cabinet  110  until a rear portion of the AHTC  116  engages and/or is spatially constrained by the REHE backing plate  168  and the AHTC front mounting bracket  160  engages and/or is spatially constrained by the one or more shelves  158 . After such insertion, electrical wires may be passed through holes  162  and connected to the REHE  166  and electrical components may be carried within a concavity of the AHTC front mounting bracket  160 . In this second configuration, a front portion of a breaker  170  associated with the REHE  166  may be allowed to protrude at least partially into the access aperture  164  of the front cover  154 , thereby allowing convenient access to the breaker  170 . In some embodiments, the AHTC front mounting bracket  160  may serve as a baffle to prevent air leakage from the multifunction cabinet  110 . 
     Referring now to  FIG. 13 , an HVAC system  200  is shown. HVAC system  200  is substantially similar to HVAC system  100  as shown in  FIG. 1 . However, HVAC system  200  differs from HVAC system  100  because rather than AHU  202  comprising a blower cabinet, a primary heat exchanger cabinet, and a multipurpose cabinet, the AHU  202  comprises a blower cabinet  206  configured to house a blower  212  and a multipurpose cabinet  210  that is configured to house each of a PHE  114  and an AHTC  116 . In some embodiments, the blower cabinet  206  may be selectively removable from the multipurpose cabinet  210 . It will be appreciated that the multipurpose cabinet  210  may, in alternative configurations of HVAC system  200 , be located at various other locations along airflow path  132 . 
     Referring now to  FIG. 14 , an HVAC system  300  is shown. HVAC system  300  is substantially similar to HVAC system  100  as shown in  FIG. 1 . However, HVAC system  300  differs from HVAC system  100  because rather than AHU  302  comprising a blower cabinet, a primary heat exchanger cabinet, and a multipurpose cabinet, the AHU  302  comprises a multipurpose cabinet  310  that is configured to house each of a blower  112 , a PHE  114 , and an AHTC  116 . 
     At least one embodiment is disclosed and variations, combinations, and/or modifications of the embodiment(s) and/or features of the embodiment(s) made by a person having ordinary skill in the art are within the scope of the disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, RI, and an upper limit, Ru, is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=RI+k * (Ru−RI), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . 50 percent, 51 percent, 52 percent, . . . 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Use of the term “optionally” with respect to any element of a claim means that the element is required, or alternatively, the element is not required, both alternatives being within the scope of the claim. Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of. Accordingly, the scope of protection is not limited by the description set out above but is defined by the claims that follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention.