Abstract:
A removable flange that is repositionable between an externally projecting flange and an internally projecting flange in a furnace housing environment. The flange is secured to the furnace housing with a suitable fastener and additionally acts as an insulation retainer. The flange prevents any insulation in the furnace housing from coming loose and obstructing a flow path in the furnace. This flange also provides means of fastening supply/return duct and/or coil cabinet to the furnace.

Description:
CROSS REFERENCE TO RELATED PATENT APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 60/884,261, filed Jan. 10, 2007. 
     
    
     BACKGROUND 
       [0002]    The present application relates generally to a flange for a furnace system. More specifically, the present application relates to a removable casing flange and insulation retainer. 
         [0003]    The basic components of a furnace or HVAC system are: a burner, a heat exchanger, an air distribution system, and a vent pipe. In the burner, gas (natural or propane) or oil is delivered and combusted to generate heat. The heat exchanger transfers the heat from the combustion gas to the air distribution system. The air distribution system, which includes a blower and ductwork, delivers the heated air throughout the home and returns cooler air to the furnace to be heated. Finally, the vent pipe or flue exhausts byproducts of combustion (such as water vapor and carbon dioxide) outside of the home. In addition, the furnace system may also include a cooling element, such as an A-coil, that operates in conjunction with an air conditioning unit (typically located outside of the home) to provide cooled air to the home instead of heated air. 
         [0004]    Typically, furnace systems in residential applications are located in the basement or a small closet in the user&#39;s home, which areas have limited space for an installed furnace system. Furthermore, efficiency standards have recently changed, thereby requiring the size of the A-coil to be increased to meet these new standards. Thus, when a newer furnace system is needed to replace an older system, often, the newer furnace can not fit into the space where the old furnace was installed because the size of the furnace unit and the newer, taller A-coil that is required is greater than the available installation space. Thus, a shorter, furnace is needed to accommodate the taller A-coil in order to be able to install a new furnace system in the same space as the old furnace system. 
         [0005]    Most furnace systems are multi poised, meaning that they can operate in a variety of positions, including up flow, down flow, and horizontal (both left and right). In addition, furnace systems may also be a single configuration, at any height. Depending upon the position, the casing flanges within the furnace may need to be removed or modified during repositioning to facilitate the installation. Often the insulation within the casing is pulled loose and obstructs airflow. As shown in  FIG. 1 , the flange  80  protrudes from the casing  82  and becomes a hindrance during repositioning of the furnace  84 , requiring the flange  80  to be removed entirely. The flanges  80  are provided on the top of the furnace system  84  by bending portions of the furnace housing  86  and casing  82 . There are several drawbacks to this type of flange  80  including the inability to relocate the flange  80 . Therefore, what is needed is a casing flange that serves as an insulation retainer and that does not have to be completely removed during repositioning of the furnace. 
         [0006]    Intended advantages of the disclosed systems and/or methods satisfy one or more of these needs or provides other advantageous features. Other features and advantages will be made apparent from the present specification. The teachings disclosed extend to those embodiments that fall within the scope of the claims, regardless of whether they accomplish one or more of the aforementioned needs. 
       SUMMARY 
       [0007]    A furnace system having a furnace housing with a plurality of sides to enclose the furnace system and insulation being disposed along the plurality of sides of the furnace housing is set forth herein. The system also has at least one flange disposed along an edge of the plurality of sides of the furnace housing. The at least one flange has at least one aperture for receiving at least one fastener and the at least one flange is repositionable between an externally projecting flange and an internally projecting flange. The at least one flange acts as a retainer for the insulation in the furnace housing. 
         [0008]    Another embodiment of this furnace system is directed to a flange having at least one aperture for receiving at least one fastener. The flange is repositionable between an externally projecting flange and an internally projecting flange, and the at least one flange acts as a retainer for the insulation in the furnace housing. 
         [0009]    One advantage of this arrangement is that the flange can be repositioned when desired. It can either protrude or be contained within the casing, if so desired. In both conditions, it would act as an insulation retainer. 
         [0010]    Another advantage of this arrangement is that the flange can be repositioned so the flange is contained within the housing and not protruding. 
         [0011]    Yet another advantage of this arrangement is that the flange serves as an insulation retainer, preventing the insulation from coming loose or obstructing airflow. 
         [0012]    Other features and advantages will be apparent from the following more detailed description of the embodiments, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the application. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is an illustration of a prior art flange. 
           [0014]      FIG. 2  is an illustration of an exemplary HVAC system disposed in a residential setting. 
           [0015]      FIG. 3  is a schematic illustration of an exemplary HVAC system according to an exemplary embodiment of the disclosure. 
           [0016]      FIG. 4  is a schematic illustration of a HVAC system according to an embodiment of the disclosure. 
           [0017]      FIG. 5  is an illustration of the flange as disposed in a furnace. 
           [0018]      FIG. 6  is a more detailed illustration of the flange as disposed in a furnace. 
           [0019]      FIG. 7  is a further illustration of the flange. 
           [0020]      FIG. 8  is a side view of the flange. 
           [0021]      FIG. 9  is an alternate embodiment of the flange. 
           [0022]      FIG. 10  is an enlarged illustration of the flange of  FIG. 9 . 
           [0023]      FIG. 11  is an enlarged illustration of the flange of  FIG. 9  in an alternate position. 
       
    
    
       [0024]    Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. 
       DETAILED DESCRIPTION 
       [0025]      FIG. 2  shows an exemplary HVAC or furnace system  100  in a typical residential setting R. The furnace system  100  has a top portion, an opposing bottom portion and a plurality of walls that are disposed substantially perpendicular to the adjacent wall, forming a rectangular enclosure. In addition, the furnace system has a door panel  198  and a lid panel  195  which allow access to the internal portions of the furnace system.  FIG. 3  illustrates an exemplary HVAC or furnace system  100  having insulation (not shown) lining the furnace housing  86 . The insulation prevents unwanted heat transfer outside of the furnace housing  86 . 
         [0026]      FIG. 4  shows a schematic arrangement of a furnace system  100 , and the internal portion of the furnace system  100 . During operation, a burner  101  combusts fuel within combustion air  102  and provides combustion products and heated air to a first heat exchanger  103 , where heat is transferred to a supply air  104 . Supply air  104  is air that is to be heated, such as interior air for a building HVAC system. Combustion air  102  is then directed into a second heat exchanger  105 , where heat is further exchanged with supply air  104 . Supply air  104  is directed over first heat exchanger  103  and second heat exchanger  105  by use of a blower  107  or similar air-moving device. Combustion air  102  is then exhausted from the system by use of an exhaust blower  109  or other air-moving device. Exhaust  111  includes air, water vapor and other combustion products. Furnace system  100  provides heat to supply air  104  by use of first heat exchanger  103  and second heat exchanger  105 . Supply air  104  is then provided to a space for heating. 
         [0027]      FIGS. 5-11  illustrate different views of one embodiment of a flange  200  used to hold the insulation  216  that lines the furnace housing  86  and position the ductwork of the furnace system. The flange  200  of the current application is repositionable from the internally facing position ( FIG. 5 ) where it secures and retains the insulation  216  in place. The flange is then reconfigured to the externally facing position ( FIG. 11 ) where it acts as an insulation retainer and a mounting means for the duct work of the furnace system. 
         [0028]    The flange  200  has one or more apertures  202  (shown in  FIG. 7 ) to receive fastening devices  204 , e.g. screws, which permit the flange  200  to be removed from its current position and relocated to a desired position by the simple disengagement and reengagement of the fastening devices  204 . This feature of the flange  200  is beneficial for furnace systems that are designed to be multi-poised, i.e., the furnace system can be configured for operation in all four positions (up-flow, down-flow, horizontal-left and horizontal-right). The flange  200  is repositionable to a position necessary depending on the particular configuration of the multi-poised furnace system  210 . For example, the flange  200  may be positioned in a retracted or internally facing position (as shown in  FIG. 5 ) and extend within the furnace system  210 . Alternatively, the flange  200  may be positioned to extend externally (as shown in  FIG. 11 ) from the furnace system  210  by simply flipping the flange  200  and reattaching it with the flange  200  extending upward. 
         [0029]    The flange  200  is a single unitary piece used on one side of the furnace housing  214 , with additional flanges  200  being used if needed for other sides of the furnace housing  86 . Alternatively, multiple flanges  200  can be used for a single side of the furnace housing  86 . The multiple flanges  200  may be connectable together to form a larger flange  200  or the multiple flanges  200  may be individually mounted on the furnace side at desired locations as shown in  FIG. 9 . In addition, the flange  200  can be a single unitary piece that extends along the perimeter of the sides of the furnace housing. The flange  200  may be cast as one piece, or each of the four pieces that extend along each side of the housing may be fastened together by a weld connection or other suitable connection. Referring specifically to  FIG. 8 , an exemplary embodiment of the flange  200  is arranged in a step shape, having a base section  220  with a first flange protrusion  222  extending upward from one side of the base section  220  and a second flange protrusion  224  extending downward from the opposite side of the base section  220 . However, the flange  200  may be configured in any suitable shape. 
         [0030]    Finally, regardless of whether the flange  200  is in a retracted position or an extended position as shown in  FIGS. 10 and 11 , respectively, the flange  200  also operates as an insulation retainer. The flange  200  is used to capture or secure insulation  216  to prevent the insulation  216  from coming loose and causing problems such as obstructing the airflow through the furnace system  210 . Further, the flange  200  is also used for securing the supply/return duct and/or coil cabinet to the furnace. The flange  200  is repositionable to accommodate supply duct or return duct variation from installation to installation. 
         [0031]    While the systems and/or methods of the application have been described with reference to several embodiments, 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 application. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the application without departing from the essential scope thereof. Therefore, it is intended that the application not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out the systems and/or methods of the application, but that the application will include all embodiments falling within the scope of the appended claims.