BLOWER HOUSING FOR AIR CONDITIONING SYSTEM

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Application No. 63/352,512, filed Jun. 15, 2022, the contents of which are incorporated by reference herein in their entirety.

BACKGROUND

Exemplary embodiments of the present disclosure relate generally to heating and cooling systems and, more particularly, to a fan housing of a blower assembly configured for use in such heating and cooling systems.

Heating, ventilation, and air conditioning (HVAC) systems typically use a blower driven by a blower motor to supply air through ducts. Existing blower housings surrounding the blower are fabricated via labor intensive process that includes crimping together a plurality of pieces. Crimping requires manual insertion of the components into a crimping machine resulting in a pinch point in the manufacturing process. In addition, the crimping machine itself is costly to buy and maintain, and use thereof results in high scrap rates.

BRIEF DESCRIPTION

According to an embodiment, a blower includes a fan wheel and a blower housing. The blower housing includes a first housing portion and a second housing portion. The second housing portion is removably connectable to the first housing portion to define a hollow interior therebetween configured to receive a fan wheel, wherein an interface between the first housing portion and the second housing portion is arranged at a central plane of the blower housing.

In addition to one or more of the features described above, or as an alternative, in further embodiments the blower housing is symmetrical about the central plane.

In addition to one or more of the features described above, or as an alternative, in further embodiments the blower housing further comprises a first sidewall, a second sidewall, and an outer wall, the first sidewall and the second sidewall being arranged at opposite sides of the outer wall.

In addition to one or more of the features described above, or as an alternative, in further embodiments the first housing portion includes the first sidewall and a first portion of the outer wall and the second housing portion includes the second sidewall and a second portion of the outer wall.

In addition to one or more of the features described above, or as an alternative, in further embodiments at least one of the first sidewall and the first portion of the outer wall are integrally formed and the second sidewall and the second portion of the outer wall are integrally formed.

In addition to one or more of the features described above, or as an alternative, in further embodiments comprising at least one flow feature formed in at least one of the first housing portion and the second housing portion.

In addition to one or more of the features described above, or as an alternative, in further embodiments the at least one flow feature is formed in the first sidewall and the second sidewall.

In addition to one or more of the features described above, or as an alternative, in further embodiments the at least one flow feature is formed in the outer wall.

In addition to one or more of the features described above, or as an alternative, in further embodiments at least one of the first housing portion and the second housing portion is formed from sheet metal shaped via a deep draw process.

In addition to one or more of the features described above, or as an alternative, in further embodiments comprising a lock engageable to restrict relative rotation between the first housing portion and the second housing portion.

In addition to one or more of the features described above, or as an alternative, in further embodiments the lock further comprises a plurality of first engagement features associated with the first housing portion and a plurality of second engagement features associated with the second housing portion, wherein the plurality of second engagement features are configured to intermesh with the plurality of first engagement members.

According to an embodiment, a method of forming a blower includes forming a first housing portion, forming a second housing portion, mounting a fan wheel within the first housing portion, and rotating the first housing portion relative to the second housing portion to couple the first housing portion to the second housing portion.

In addition to one or more of the features described above, or as an alternative, in further embodiments the first housing portion further comprises a first edge having a first connector flange and the second housing portion further comprises a second edge having a second connector flange. The method also includes aligning the first connector flange and the second connector flange within a central plane prior to rotating the first housing portion.

In addition to one or more of the features described above, or as an alternative, in further embodiments the first connector flange includes a plurality of first engagement features and the second connector flange includes a plurality of second engagement features.

In addition to one or more of the features described above, or as an alternative, in further embodiments rotating the first housing portion relative to the second housing portion further comprises rotating the plurality of first engagement features into engagement with the plurality of second engagement features to couple the first housing portion to the second housing portion.

In addition to one or more of the features described above, or as an alternative, in further embodiments installing at least one fastener through the first connector flange and the second connector flange after rotating the first housing portion relative to the second housing portion.

In addition to one or more of the features described above, or as an alternative, in further embodiments at least one of forming the first housing portion and forming the second housing portion further comprises deep drawing a sheet metal.

In addition to one or more of the features described above, or as an alternative, in further embodiments forming the first housing portion further comprises forming a first sidewall and a first portion of an outer wall of the blower housing, and forming the second housing portion further comprises formed a second sidewall and a second portion of the outer wall of the blower housing.

In addition to one or more of the features described above, or as an alternative, in further embodiments forming at least one flow feature in at least one of the first sidewall and the second sidewall.

In addition to one or more of the features described above, or as an alternative, in further embodiments forming at least one flow feature in at least one of the first portion of the outer wall and the second portion of the outer wall.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:

FIG. 1 is a perspective view of an example of a heating, ventilation, and air conditioning (HVAC) system, illustrated as a gas furnace;

FIG. 2 is a perspective view of an exemplary blower assembly of the gas furnace shown in FIG. 1 according to an embodiment;

FIG. 3 is a top perspective view of an exemplary blower assembly, according to an embodiment;

FIG. 4 is a side perspective view of an exemplary blower housing, according to an embodiment;

FIG. 5 is a perspective view of an exemplary housing portion of the blower housing of FIG. 4 according to an embodiment;

FIG. 6 is another perspective view of an exemplary housing portion of the blower housing of FIG. 4 according to an embodiment; and

FIG. 7 is a top perspective view of an exemplary blower assembly according to an embodiment.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.

With reference to FIG. 1, an example of a heating, ventilation, and air conditioning (H VAC) system, depicted as a gas furnace, such as used in a residential air conditioning system for example, is illustrated generally at 20. The gas furnace system 20 includes a housing 22 having a plurality of exterior walls 24, 26, 28 and an interior dividing wall 30 that forms a heat exchange portion 32 and a blower portion 34. Heat exchange portion 32 includes a component support wall 36 which, as will be discussed more fully below, provides structure for mounting various components of the gas furnace system 20. Housing 22 is also shown to include an access panel 38 that provides access to the blower portion 34 and another access panel (not shown) that provides access to heat exchange portion 32.

The gas furnace system 20 additionally includes a burner assembly 40 mounted to component support wall 36. Burner assembly 40 includes a burner box 42 and a gas valve 44. Burner assembly 40 combusts a fuel, in the form of gas, to generate heat used to condition a comfort zone such as living spaces, workspaces and the like. As will be discussed more fully below, products of combustion or exhaust gases generated by the burning of the fuel are expelled to ambient. In the embodiment shown, burner assembly 40 is operatively connected to a primary heat exchanger 46 arranged within heat exchange portion 32. Primary heat exchanger 46 is operatively coupled to a condensing heat exchanger 48. Condensing heat exchanger 48 includes a plurality of heat exchange members 50. With this arrangement, a blower assembly 52 arranged within the blower portion 34 draws in air from a space to be heated. The air is guided over primary heat exchanger 46 and heat exchange members 50 of condensing heat exchanger 48 such that the air is heated before being re-introduced into the space.

During operation of the gas furnace system 20, moisture from the products of combustion condenses within the condensing heat exchanger 48. This moisture collected and passed on to an external drain (not shown). The moisture is guided to a condensate collector box 54. Condensate collector box 54 is secured to component support wall 36. The moisture is collected in condensate collector box 54 and passed to a condensate trap 56 and on to the external drain. Gas furnace system 20 further includes an inducer fan assembly 58 mounted to condensate collector box 54. Inducer fan assembly 58 creates an air flow that establishes a draft which draws the products of combustion from burner box 42 through primary heat exchanger 46 and heat exchange members 50 of the condensing heat exchanger 48. More specifically, inducer fan assembly 58 produces a pressure rise and flow rate to achieve a desired combustion performance while overcoming flow losses within gas furnace system 20. The products of combustion are then exhausted through a flue vent 60. It should be understood that the gas furnace system illustrated and described herein is intended as an example only and that any suitable HVAC system is within the scope of the disclosure.

With reference now to FIG. 2, an example of a blower assembly 52 is illustrated in more detail. Although the blower assembly 52 is illustrated and described herein with reference to a furnace, it should be understood that the blower assembly 52 may be used in other suitable applications, such as in an air handling unit of an HVAC and/or refrigeration system for example. The blower assembly 52 includes a fan wheel 62 positioned within a blower housing 64. The blower housing 64 has an outer wall 66 having a scroll-shaped length that extends from a first end 68 to an opposite second end 70. The first end 68 the second end 70 define opposite sides of an outlet opening 72 of the blower housing 64. Although the outlet opening 72 is illustrated as being generally rectangular in shape, embodiments where the outlet opening 72 is another shape are also contemplated herein.

The blower housing 64 additionally includes a first sidewall 74 and a second sidewall 76. As seen in the Figures, portions of the peripheries of the first sidewall 74 and the second sidewall 76 are arranged at opposite sides of the outer wall 66. The first sidewall 74 may have a first straight edge portion 78 extending between the outer wall first end 68 and the outer wall second end 70 and the second sidewall 76 may similarly have a second straight edge portion 80 extending between the outer wall first end 68 and the outer wall second end 70. The first sidewall 74 includes a first aperture 82 and the second sidewall 76 includes a second aperture 84. In an embodiment, the first and second apertures 82 are substantially identical in size and shape and are position in axial alignment with one another.

With reference now to FIGS. 3-7, in an embodiments, the blower housing 64 is formed from a first housing portion 90 and a second housing portion 92. The first housing portion 90 and the second housing portion 92 may be removably connectable with one another at a centrally located plane P (FIG. 3). The first housing portion 90 and the second housing portion 92 may be similar. For example, in an embodiment, the first housing portion 90 and the second housing portion 92 may be substantially identical but with symmetrical or opposite orientations.

In the illustrated, non-limiting embodiment, the first housing portion 90 includes the first sidewall 74 and a first portion 94 of the outer wall 66. In an embodiment, the first sidewall 74 and the first portion 94 of the outer wall 66 are integrally formed, such as from a piece of sheet metal via a deep draw process. Further, a first connector flange 96 may be arranged at the edge 98 of the first portion 94 of the outer wall 66. In such embodiments, the first connector flange 96 may extend over the entirety of edge 98 or over only a portion of the edge 98. The second housing portion 92 includes the second sidewall 76 and a second portion 100 of the outer wall 66. In an embodiment, the second sidewall 76 and the second portion 100 of the outer wall 66 are integrally formed. A second connector flange 102 may be arranged at an edge 104 (see FIG. 4) of the second portion 100 of the outer wall 66. The second connector flange 102 may extend over the entire edge 104 or over only a portion of the edge 104. In an embodiment, the first connector flange 96 and the second connector flange 102 extend about a same portion of the respective edges 98, 104.

At least one flow feature 105 configured to affect the flow generated by the fan wheel 62 may be formed into the blower housing 64. With reference to FIG. 7, in an embodiment, the flow features 105 include one or more grooves and/or ridges that extend into the interior of the blower housing 64; however, any suitable flow feature is contemplated herein. As shown, the flow features 105 are formed into the sidewalls 74, 76 and, in an embodiment, wrap in a spiral-like configuration about the apertures 82, 84. Alternatively, or in addition, one or more flow features 105 may be formed in the first portion 94 and/or the second portion 100 of the outer wall 66. In an embodiment, the flow features 105 formed into the blower housing 64 are substantially symmetrical about the central plane P to create a balanced flow within the blower housing 64. However, in other embodiments, the flow features 105 formed in the blower housing 64 are asymmetric relative to the central plane P.

A lock 106 may be formed at the interface between the first housing portion 90 and the second housing portion 92. In an embodiment, the lock 106 is a bayonet locking system including one or more first engagement features 108 arranged at the first housing portion 90 and one or more second engagement features (not shown) arranged at the second housing portion 92. The second engagement features are complementary to the first engagement features 108. In operation, one of the first housing portion 90 and the second housing portion 92 is rotated relative to the other of the first housing portion 90 and the second housing portion 92 within plane P. During this rotation, the first engagement features 108 are configured to abut or intermesh with the corresponding second engagement members to restrict movement of the first housing portion 90 relative to the second housing portion 92. Once the first housing portion 90 and the second housing portion 92 are coupled, one or more fasteners may be installed through the flanges 96, 102 to further restrict relative rotation thereof. However, in some embodiments, fasteners need not be included. It should be understood that the lock 106 illustrated and described herein is intended as an example only and any suitable mechanism for coupling the first housing portion 90 and the second housing portion 92 such that the flanges 96, 102 and/or the edges 98, 104 thereof abut one another is contemplated herein.

A method of forming the blower housing 64 includes forming both the first housing portion 90 and the second housing portion 92. As previously noted, one or both housing portion 90, 92 may be formed from via a deep drawing process. By using such a process, the at least one flow feature may be integrally formed with one or both of the first and second housing portions 90, 92 during the forming process. Once formed, the first and second housing portions 90, 92 may be stacked such that the first connector flange 96 and the second connector flange 102 are arranged within the same central plane. The first housing portion 90 and the second housing portion 92 are rotated relative to one another when the connector flanges 96, 102 are in the same plane. As a result of this rotation, each of the plurality of first engagement features 108 is separated from a corresponding second engagement feature (not shown). One of the first housing portion 90 and the second housing portion 92 is then rotated relative to the other of the first housing portion 90 and the second housing portion 92 into alignment. In the aligned position, the first engagement features 108 are intermeshed with the second engagement features and the first and second housing portions 90, 92 are substantially symmetrical about the central plane P. One or more fasteners may then be installed through the adjacent first and second connectors flanges 96, 102, to restrict relative rotation between the housing portions 90, 92.

It should be understood that one or more components of the blower, such as a fan wheel or motor for example, may be installed within at least one of the first housing portion 90 and the second housing portion 92 prior to coupling the first and second housing portions 90, 92. Similarly, one or more components of the blower, may alternatively or additionally be mounted to one or both of the housing portions 90, 92 after the housing portions 90, 92 are coupled.

A blower housing 64 as illustrated and described herein is easily produced via automation, without relying on a complex crimping machine/process, thereby resulting in reduced production time and decreased waste. Further, the blower housing 64 may have an improved air flow, increased stiffness, and reduced manufacturing tolerances.

The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.

While the present disclosure has been described with reference to an exemplary embodiment or 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 present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.