HVAC SYSTEM HAVING MODULAR COMPONENTS

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional application claiming priority to U.S. Provisional Application No. 63/685,464, filed on Aug. 21, 2024, the entire content of which is hereby incorporated by reference herein in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

BACKGROUND

Heating, ventilation and air conditioning (HVAC) systems provide warm and cool air to residential and commercial buildings using multiple components. A combination of different components may form the HVAC system including an air conditioner, air handler, thermostat, humidifier, air purifier and the like. The combination of these components ensures temperature and air quality needs for the building or space of interest. The combination of the components may depend on a variety of factors including location of the building or space of interest, size of the building or space of interest, price range, preferences for the building or space of interest (e.g., energy efficiency, noise reduction, humidity), and/or the like.

Poor airflow is one of the most common HVAC problems resulting from clogged air filters, obstructed condenser units, blocked vents, thermostat issue, refrigerant leaks, dirty coils, and the like. According to a survey in California, 65% of residential air conditioning units and 71% of commercial air conditioning units were involved with faults during the lifecycle of the unit. See Proceedings of 2002 American Council for an Energy-Efficient Economy (ACEEE) summer study (2002) Pacific Grove, August 18-23. These typical faults included control faults, sensor faults and equipment faults, with each fault resulting in a service call for repair.

There exists a need within the industry to reduce the time and cost of service repair while also providing increased options to ensure temperature and air quality needs for the building or space of interest.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary embodiment of an HVAC system in accordance with the present disclosure.

FIG. 2A is a perspective view of an exemplary embodiments of a housing for use in an HVAC system in accordance with the present disclosure.

FIG. 2B is a sectional view of the housing illustrated in FIG. 2A.

FIG. 3A is a first sectional view of an exemplary embodiment of a modular component for use in the HVAC system illustrated in FIG. 1.

FIG. 3B is a second sectional views of the exemplary embodiment of the modular component for use in the HVAC system illustrated in FIG. 1.

FIG. 4A is a sectional view of another exemplary embodiment of a modular component for use in the HVAC system illustrated in FIG. 1.

FIG. 4B is a perspective view of an exemplary embodiments of a housing for use in an HVAC system in accordance with the present disclosure.

FIG. 4C is a perspective view of an exemplary embodiment of an electrical connector for use in an HVAC system in accordance with the present disclosure.

FIG. 5 is a sectional view of an exemplary embodiment of a modular component including a filtration system for use in an HVAC system in accordance with the present disclosure.

FIG. 6A a perspective view of an exemplary embodiment of another modular component including a filtration system for use in an HVAC system with a filtration media roll and the elongated sheet of filter material being recovered on a filter recovery roller in accordance with the present disclosure.

FIG. 6B is a perspective view of an exemplary embodiment of another modular component including a filtration system for use in an HVAC system without showing the filtration media roll and the elongated sheet of filter material on the filter recovery roller in accordance with the present disclosure.

FIG. 7A is a perspective view of an exemplary embodiment of a modular component including a blower system for use in an HVAC system in accordance with the present disclosure.

FIG. 7B is a plan view of the modular component illustrated in FIG. 7.

FIG. 8 is a plan view of an exemplary embodiment of a modular component including a mechanical unit for cooling air use in an HVAC system in accordance with the present disclosure.

FIG. 9 is a perspective view of an exemplary mechanical unit use in an HVAC system in accordance with the present disclosure.

FIG. 10 is a sectional view of an exemplary embodiment of a modular component including an electric heat system for use in an HVAC system in accordance with the present disclosure.

FIG. 11 is a block diagram of an exemplary embodiment of an HVAC system in accordance with the present disclosure.

FIG. 12 illustrates an exemplary method for cooling air using an HVAC system in accordance with the present disclosure.

FIG. 13 illustrates an exemplary method for heating air using an HVAC system in accordance with the present disclosure.

DETAILED DESCRIPTION

Before explaining at least one embodiment of the inventive concept(s) in detail by way of exemplary language and results, it is to be understood that the inventive concept(s) is not limited in its application to the details of construction and the arrangement of the components set forth in the following description. The inventive concept(s) is capable of other embodiments or of being practiced or carried out in various ways. As such, the language used herein is intended to be given the broadest possible scope and meaning; and the embodiments are meant to be exemplary-not exhaustive. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.

Unless otherwise defined herein, scientific and technical terms used in connection with the presently disclosed inventive concept(s) shall have the meanings that are commonly understood by those of ordinary skill in the art. Further, unless otherwise required by context, singular terms shall include pluralities and plural terms shall include the singular. The foregoing techniques and procedures are generally performed according to conventional methods well known in the art and as described in various general and more specific references that are cited and discussed throughout the present specification.

All patents, published patent applications, and non-patent publications mentioned in the specification are indicative of the level of skill of those skilled in the art to which this presently disclosed inventive concept(s) pertains. All patents, published patent applications, and non-patent publications referenced in any portion of this application are herein expressly incorporated by reference in their entirety to the same extent as if each individual patent or publication was specifically and individually indicated to be incorporated by reference.

All of the compositions, assemblies, systems, kits, and/or methods disclosed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions, assemblies, systems, kits, and methods of the inventive concept(s) have been described in terms of particular embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the methods described herein without departing from the concept, spirit, and scope of the inventive concept(s). All such similar substitutions and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the inventive concept(s) as defined by the appended claims.

As utilized in accordance with the present disclosure, the following terms, unless otherwise indicated, shall be understood to have the following meanings:

The use of the term “a” or “an” when used in conjunction with the term “comprising” in the claims and/or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” As such, the terms “a,” “an,” and “the” include plural referents unless the context clearly indicates otherwise. Thus, for example, reference to “a compound” may refer to one or more compounds, two or more compounds, three or more compounds, four or more compounds, or greater numbers of compounds. The term “plurality” refers to “two or more.”

The use of the term “at least one” will be understood to include one as well as any quantity more than one, including but not limited to, 2, 3, 4, 5, 10, 15, 20, 30, 40, 50, 100, etc. The term “at least one” may extend up to 100 or 1000 or more, depending on the term to which it is attached; in addition, the quantities of 100/1000 are not to be considered limiting, as higher limits may also produce satisfactory results. In addition, the use of the term “at least one of X, Y, and Z” will be understood to include X alone, Y alone, and Z alone, as well as any combination of X, Y, and Z. The use of ordinal number terminology (i.e., “first,” “second,” “third,” “fourth,” etc.) is solely for the purpose of differentiating between two or more items and is not meant to imply any sequence or order or importance to one item over another or any order of addition, for example.

The use of the term “or” in the claims is used to mean an inclusive “and/or” unless explicitly indicated to refer to alternatives only or unless the alternatives are mutually exclusive. For example, a condition “A or B” is satisfied by any of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

As used herein, any reference to “one embodiment,” “an embodiment,” “some embodiments,” “one example,” “for example,” or “an example” means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearance of the phrase “in some embodiments” or “one example” in various places in the specification is not necessarily all referring to the same embodiment, for example. Further, all references to one or more embodiments or examples are to be construed as non-limiting to the claims.

Throughout this application, the term “about” is used to indicate that a value includes the inherent variation of error for a composition/apparatus/device, the method being employed to determine the value, or the variation that exists among the study subjects. For example, but not by way of limitation, when the term “about” is utilized, the designated value may vary by plus or minus twenty percent, or fifteen percent, or twelve percent, or eleven percent, or ten percent, or nine percent, or eight percent, or seven percent, or six percent, or five percent, or four percent, or three percent, or two percent, or one percent from the specified value, as such variations are appropriate to perform the disclosed methods and as understood by persons having ordinary skill in the art.

As used in this specification and claim(s), the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”), or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

The term “or combinations thereof” as used herein refers to all permutations and combinations of the listed items preceding the term. For example, “A, B, C, or combinations thereof” is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, expressly included are combinations that contain repeats of one or more item or term, such as BB, AAA, AAB, BBC, AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context.

As used herein, the term “substantially” means that the subsequently described event or circumstance completely occurs or that the subsequently described event or circumstance occurs to a great extent or degree. For example, when associated with a particular event or circumstance, the term “substantially” means that the subsequently described event or circumstance occurs at least 80% of the time, or at least 85% of the time, or at least 90% of the time, or at least 95% of the time. For example, the term “substantially adjacent” may mean that two items are 100% adjacent to one another, or that the two items are within close proximity to one another but not 100% adjacent to one another, or that a portion of one of the two items is not 100% adjacent to the other item but is within close proximity to the other item.

As used herein, the phrases “associated with” and “coupled to” include both direct association/binding of two components to one another as well as indirect association/binding of two components to one another.

Circuitry, as used herein, may be analog and/or digital components, or one or more suitably programmed processors (e.g., microprocessors) and associated hardware and software, or hardwired logic. Also, “components” may perform one or more functions. The term “component,” may include hardware, such as a processor (e.g., microprocessor), an application specific integrated circuit (ASIC), field programmable gate array (FPGA), a combination of hardware and software, and/or the like. The term “processor” as used herein means a single processor or multiple processors working independently or together to collectively perform a task.

Software may include one or more computer readable instructions that when executed by one or more components cause the component to perform a specified function. It should be understood that the algorithms described herein may be stored on one or more non-transitory memory. Exemplary non-transitory memory may include random access memory, read only memory, flash memory, and/or the like. Such non-transitory memory may be electrically based, optically based, and/or the like.

Turning now to the drawings, and in particular FIGS. 1 and 2A, certain non-limiting embodiments thereof include an HVAC system 10 and methods of use. The HVAC system 10 generally includes a housing 12 having multiple modular components 14 (e.g., modular components 14a-14d as ilustrated in FIG. 1) configured to provide air at a distinct and/or predetermined temperature (e.g., cool air or warm air in comparison to air within the current environment) to a building and/or space of interest 16. Each modular component 14 may be slidaby received within the housing 12. Each modular component 14 may be installed and removed separate from other modular components. To that end, each modular component 14 may be removed and serviced minimizing technical installation. Additionally, one or more modular components 14 or portions within each modular component may be serviced and/or upgraded individually by removing the single modular component 14 from the housing 12.

Generally, the housing 12 may include a top panel 18 and a bottom panel 20 with a first side panel 22 and a second side panel 24. Each side panel 22 and 24 extends between the top panel 18 and the bottom panel 20. In some embodiments, a third side panel 26 may optionally be positioned between the first side panel 22 and the second side panel 24 and extend between the top panel 18 and the bottom panel 20. In some embodiments shown in FIG. 2B, the first side panel 22, the second side panel 24 and/or the third side panel 26 may include an interior wall 23 and an exterior wall 25 forming an enclosed cavity 27. The enclosed cavity 27 may house electrical connections, condensation apparatus, and the like.

Referring to FIGS. 2A and 2B, one or more divider frames 28 may be positioned within the housing 12 defining one or more compartments 30 with each compartment 30 arranged end to end of the housing 12 from a first end 32 to a second end 34. In some embodiments, the divider frames 28 may extend between the first side panel 22 to the second side panel 24. In some embodiments, a first set of divider frames 28 may extend from the first side panel 22 and a second set of corresponding divider frames 28 may extend from the second side panel 24. Each modular component 14 may be slidably received within the one or more compartments 30 within the housing 12. Each modular component 14 forms at least a portion of the HVAC system 10 providing air at a distinct and/or predetermined temperature to a building and/or space of interest 16 in accordance with the present disclosure.

In some embodiments, the HVAC system 10 may be installed within a preexisting framework of a wall as illustrated in FIG. 1. In some embodiments, the HVAC system 10 may be provided as a portable unit. For example, the HVAC system 10 may be a self-contained portable system configured to provide air at a distinct and/or predetermined temperature for a room, building and/or space of interest 16. Referring again to FIGS. 1 and 2A, generally, air is cycled from an interior area of the building or space of interest 16 via a return air inlet 42 and back out to the space of interest 16 via a supply air exit 44 in the direction of arrows 46 in FIG. 2A. In some embodiments, the air exiting the supply air exit 44 may be contained within a supply housing 48 prior to entry within the one or more duct 50 for transport to the space of interest 16. It should be noted that in some embodiments, the supply air exit 44 may provide air directly to the space of interest 16. In some embodiments, air may be cycled from an area exterior to the space of interest 16 and/or back out to the exterior area.

FIGS. 3A and 3B illustrate an exemplary modular component 14 in accordance with the present disclosure. Generally, the modular component 14 is a box-shaped container configured to be slidably received into the compartment 30 (shown in FIG. 2). The modular component 14 may include a first pair of opposing sides 52a and 52b and a second pair of opposing sides 54a and 54b. The sides 52a, 52b, 54a, and 54b are connected to form a square or rectangular shape having an opening 55 there between. It should be noted that based on design considerations to be slidably received into the compartment 30 and provide air as detailed within the description, the modular component 14 may have more than four sides and may form any fanciful shape.

The first pair of opposing sides 52a and 52b may be configured to be slidably received within the compartment 30 (shown in FIG. 2). To that end, one or both sides 52a and 52b may include a slide 56. The slide 56 may include, but is not limited to, a wooden slide, a wheel drawer slide, a ball bearing slide, a telescoping ball bearing slide, or the like. Generally, the slide 56 may be a side-mounted slide as illustrated in FIG. 3. In some embodiments, the slide 56 may be an under-mounted slide.

The second pair of opposing sides 54a and 54b form the first end 58 and the second end 60 of the modular component 14. During use, the first end 58 of the modular component 14 is first to be received within the compartment 30 (shown in FIG. 2). That is, in some embodiments, the first end 58 of the modular component 14 may be positioned adjacent to the third panel of the housing 12 (shown in FIG. 2). The side 54a at the second end 60 of the modular component 14 may include a handle 62. In some embodiments, the handle 62 may include a latch and/or lock. For example, FIGS. 3A and 3B illustrate an exemplary D-ring latch 64 configured to secure the modular component 14 within the compartment 30 (shown in FIG. 2). The D-ring latch 64 includes the handle 62, a cam 66, and a plurality of rods 68. By rotating the cam 66, the plurality of rods 68 may engage and disengage with grooves 70 formed in the compartment 30 (shown in FIG. 2A).

To engage the modular component 14 within the compartment 30 (shown in FIG. 2), the first end 58 of the modular component 14 may be positioned in the compartment 30. The slide 56 may engage with the compartment 30 such that the modular component 14 may be slidably received and guided within the compartment 30 until the first end 58 of the modular component 14 is adjacent to the third side panel 26 of the housing 12. The modular component 14 may be fully received within the compartment 30 when, for example, the second end 60 is flush within the housing 12, the first end 58 of the modular component 14 is adjacent to the third side panel 26, or the plurality of rods 68 align with the grooves 70 in the compartment 30. Once the modular component 14 is fully received within the compartment 30, the cam 66 of the D-ring latch 64 may be rotated such that the plurality of rods 68 engage with the grooves 70 in the compartment 30. To disengage the modular component 14 from the compartment 30, the cam 66 of the D-ring latch 64 may be rotated such that the plurality of rods 68 disengage with the grooves 70 in the compartment 30. A force may be applied using the handle 62 to remove the modular component 14 from the compartment 30.

FIGS. 4A and 4B illustrate an exemplary embodiment of a modular component 14e configured to provide electrical connection and disconnection of the modular component 14e to the housing 12 (shown in FIG. 2). Generally, the exemplary modular component 14e includes the D-ring latch 64 shown in FIG. 4A. Additionally, the plurality of rods 68 may include one or more drive shafts 80. Each drive shaft 80 may be configured to connect with a locking shaft 82 having an ear 84. The ear 84 of the locking shaft 82 is configured to engage with a pressure power switch 86 positioned on the exterior of the modular component 14e. The pressure power switch 86 interrupts or completes an electrical circuit that supplies power to the modular component 14e. To that end, the modular component 14e may be inserted and slidably received within the housing 12 as described in further detail herein. The cam 66 of the D-ring latch 64 may be tuned to engage the plurality of rods 68 within the one or more locking shafts 82. The drive shaft 80 may be configured to rotate the ear 84 engaging the pressure power switch 86 and providing power to the modular component 14e.

The modular component 14e also includes an electrical connector 90 configured to receive power and be attached to an exterior surface of the modular component 14e. An exemplary electrical connector 90 is illustrated in FIG. 4C. The electrical connector 90 includes a plurality of rods 92. The rods 92 may be formed of metal (e.g., steel). Each rod 92 may be positioned within a holder 94 secured within a casing 96. Each holder 94 may be formed of metal (e.g., steel). In some embodiments, the holder 94 may be formed of magnetized metal. In some embodiments, the holder 94 may include a beveled end larger than the casing 96. The casing 96 may be formed of rigid material such as, for example, plastic. Each electrical connector 90 may transfer power via one or more wire connectors 98. To that end, the electrical connector 90 receives power and transfers the power via one or more wire connectors 98 to the modular component 14e. The electrical connector 90 may be positioned on the exterior surface of the modular component 14e via adhesive, mechanical attachment, and/or the like. For example, one or more bolts 100 may secure the electrical connector 90 to the modular component 14e. In the example shown, two bolts 100 secure the electrical connector 90 to the first end 58 of the modular component 14e.

The housing 12 may include a power distribution system 102 having a plurality of distribution connectors 104 and voltage wires 106. In some embodiments, each modular component 14 may be paired with one distribution connector 104 shown as distribution connectors 104a-104d in FIG. 4B. Attachment of the modular component 14 to the distribution connector 104 may provide additional securement of the modular components 14 within the housing 12. In some embodiments, the electrical connector 90 may be a magnetized electrical connector and the corresponding distribution connector 104 may include one or more magnetic polar opposite portions. To that end, the magnetization between the electrical connector 90 and the corresponding distribution connector 104 provides additional stabilization and/or attachment between the modular component 14 and the housing 12.

Power is transferred within the power distribution system 102 via voltage wires 106. The power distribution system 102 may also include a grounding wire 108. The power distribution system 102 receives power from an external source via terminals 110 of the voltage wires 106 and grounding wire 108 and distributes power to the modular components 14 within the housing 12 via the distribution connectors 104 to the electrical connectors 90.

In some embodiments, the power distribution system 102 may be positioned within a cavity 27 formed between the interior wall 23 and exterior wall 25 of the first side panel 22, the second side panel 24 and/or the third side panel 26. Insulation may optionally be provided about the power distribution system 102. In some embodiments, the power distribution system 102 may be positioned between the first side panel 22, second side panel 24 or third side panel 26 and the modular components 14.

Referring to FIGS. 5-10, the HVAC system 10 may include multiple modular components 14 that include a filtration system, blower system, mechanical unit, and electrical heat system described in further detail herein.

FIG. 5 illustrates an exemplary embodiment of the modular component 14a including a filtration system 120. The filtration system 120 may be positioned within the modular component 14a at the first end 32 of the housing 12. Generally, the filtration system 120 may include filter 122 formed of fibrous or porous material configured to remove particulates. The filter 122 may be positioned within the modular component 14a via one or more projections 124 extending from one or more sides 52a, 52b, 54a, 54b of the modular component 14a. The filter 122 may be a fiberglass air filter, pleated air filter, high-efficiency particulate air (HEPA) air filter, ultraviolet light (UV) filter, and/or the like. In some embodiments, multiple filters 122 may be positioned within the modular component 14a forming the filtration system 120.

FIGS. 6A and 6B illustrate an exemplary embodiment of a filtration system 120a for use within the modular component 14a. The filtration system 120a includes a filter storage roller 130 and a filter recovery roller 132 with one or more support rollers 134 positioned therebetween. Generally, the filter storage roller 130 provides an elongated sheet 136 of filter material to pass to the filter recovery roller 132. The filter material may be fibrous or porous material configured to remove particulates. A filtration media roll 140 of the elongated sheet 136 of filter material may be positioned on the filter storage roller 130. The filter storage roller 130 may be formed of a rod 142 with at least one end configured to be removed from the modular component 14a for loading the filtration media roll 140. For example, the rod 142 may be configured to pivot about one end such that the alternating end of the rod 142 may be moved external to the modular component 14a for loading the filtration media roll 140. The one or more support rollers 134 are configured to keep the elongated sheet 136 of filter material taut (i.e., pulled tight and not slack) such that particulates are able to be captured within the filter material. In some embodiments, the modular component 14a may further include an isolated compartment configured to house the filter storage roller 130 and the filter recover roller 132. For example, the isolated compartment may be separate from the flow of air through the HVAC system 10 as described in detail herein.

In some embodiments, the filter storage roller 130 and the filter recovery roller 132 may be positioned in parallel on the first side 54a of the modular component 14a. The filter recovery roller 132 may include a rod 144 with an actuator 146 (e.g., motor) positioned at one end of the rod 144. The actuator 146 is configured to generate rotational force used to turn the filter recovery roller 132 such that the elongated sheet 136 of filter material is passed from the filter storage roller 130 to the filter recovery roller 132. In some embodiments, the actuator 146 is powered to rotate the filter recovery roller 132 passing the elongated sheet 136 of filter material from the filter storage roller 130 to the filter recovery roller 132 along a path traversing an air flow path between the filter storage roller 130 to the one or more support rollers 134, and from the one or more support rollers 134 to the recovery roller 132. The one or more support rollers 134 support and guide the elongated sheet 136 of filter material as the elongated sheet 136 of material passes from the filter storage roller 130 to the filter recovery roller 132.

In some embodiments, the filtration system 120a includes a filtration sensor 150. The filtration sensor 150 may be, for example, a cubic feet per minute (CFM) sensor configured to measure airflow volume. In some embodiments, during use, the elongated sheet 136 of filter material may be cycled based on readings from the filtration sensor 150. To that end, the elongated sheet 136 of filter material may be in a first position. The filtration sensor 150 may determine a reduction in airflow over the course of use of the elongated sheet 136 of filter material. The filtration sensor 150 may signal to the actuator 146 to rotate the filter recovery roller 132 placing the elongated sheet in a second position increasing airflow through the elongated sheet 136 of filter material. For example, the filtration sensor 150 transmits a signal to the actuator 146 when airflow volume decreases below a predetermined threshold during a predetermined time period. The actuator 146 receives the signal and rotates the rod 144 and/or the filter recovery roller 132. Each movement between the first position and the second position may be considered a single cycle. In some embodiments, the HVAC system 10 may be configured to pause operation (e.g., conditioning of air, fan activity) during movement between the first position and the second position. In some embodiments, the filtration system 120a may be configured to determine a number of cycles completed. For example, the filtration system 120a may include circuitry, e.g., processor 152 configured to determine a number of cycles completed based on movement of the elongated sheet 136 of the filter material and/or readings provided from the filtration sensor 150. In some embodiments, the processor 152 may include a display configured to display a number of cycles completed or remaining for the filtration media roll 140. In some embodiments, the processor 152 may transmit data to an external processor and/or server. For example, the processor 152 may transmit data related to the number of cycles remaining for the filtration media roll 140 such that an additional filtration media roll may be provided to the filtration system 120a prior the filtration media roll 140 running low or out of the elongated sheet 136 of filter material.

FIGS. 7A and 7B illustrate an exemplary embodiment of the modular component 14b including a blower system 156 configured to cycle air from outside of the HVAC system 10 through the HVAC system 10 (shown in FIG. 1) in accordance with the present disclosure. In some embodiments, the blower system 156 may be positioned within the modular component 14b adjacent to the modular component 14a having the filtration system 120. Generally, the modular component 14b having the blower system 156 may be separated into a first portion 158 having circuitry and a second portion 160 having one or more blower fans 162. The second portion 160 having the one or more blower fans 162 may be open to air transmitted from the filtration system 120 within the modular component 14a such that air flows from the modular component 14a through the second portion 160 of the modular component 14b. In some embodiments, air may additionally flow through the first portion 158 of the modular component 14b.

Depending on design considerations of the area of interest, the blower system 156 may include multiple blower fans 162 or a singular blower fan. For example, in FIG. 7A, the blower system 156 includes a plurality of blower fans 162a, 162b, 162c and 162d. Blower fans 162a-162d may be high velocity variable speed blower fans, for example. In some embodiments, one or more partition walls may be positioned between the blower fans 162. For example, in FIG. 7A, a first partition wall 164a and a second partition wall 164b separate each of the blower fans 162. Additionally, a third partition wall 164c separates a processor 170 and wire connectors 98 within the first portion 158 of the modular component 14b from the blower fans 162 within the second portion 160 of the modular component 14b. In some embodiments, one or more of the blower fans 162 may be mounted on one or more of the partition walls 164 and/or one or more blower fans 162 may be mounted on one or more sides 52a, 52b or 54b of the modular component 14b.

FIG. 8 illustrates an exemplary embodiment of the third modular component 14c including a mechanical unit 200 configured to perform conditioning of air. Generally, the third modular component 14c may include a first section 202 and a second section 204 isolated from the first section 202 via a wall 206. The second section 204 has a cavity to receive air from the second modular component 14b (shown in FIG. 1). This third modular component 14c may be configured to provide air that is heated or air that is cooled via use of a reversing valve as described in detail herein.

The third modular component 14c includes a first side 208 and a second opposing side 210. A third side 212 interconnects the first side 208 and the second side 210. A fourth side 213 is positioned opposite the third side 212 and interconnects the first side 208 and the second side 210. In some embodiments, sides 208, 210, 212 and 213 are similar in configuration to sides 52a, 52b, 54a and 54b described herein. The second section 204 houses a evaporator coil 214 and a condenser 216. In some embodiments, the evaporator coil 214 may be positioned between and/or attached to the third side 212 and the wall 206. An exemplary evaporator coil 214 may include, for example, Kolpak Model 18828, manufactured by Kolpak having a primary place of business in Parsons, TN. It should be noted that other evaporator coils 214 may be used depending on design considerations for the area of interest as described herein.

Referring to FIGS. 8 and 9, the condenser 216 may include a condenser coil 218 configured to transverse along a portion of the first side 208, the third side 212 and the second side 210 of the third modular component 14c. For example, the condenser coil 218 may be a U-shaped condenser coil having three sides 220, 222 and 224 positioned adjacent to the first side 208, the third side 212 and the second side 210 respectively within the second section 204 of the third modular component 14c. In some embodiments, the condenser coil 218 may be attached and secured between a double wall (e.g., sheet metal) cavity within the third modular component 14c. In some embodiments, the condenser coil 218 may be foam insulated within the double wall cavity.

The first section 202 of the third modular component 14c houses a receiver tank 230, a compressor 232 and reversing valve 234. The reversing valve 234 is configured to allow for the third modular component 14c to provide air that is heated or air that is cooled depending on flow of fluid through the system. Generally, the receiver tank 230 is coupled to the condenser 216 and reversing valve 234 via interconnecting refrigerant tubing 236. An exemplary receiver tank 230 includes, but is not limited to, Copeland Model 977-0431-03, manufactured by Emerson having a primary place of business in St. Louis, MO. An exemplary reversing valve 234 includes, but is not limited to, SANHUA 4-Way Reversing Valve, manufactured by Sanhua having a primary place of business in Houston, TX. The compressor 232 is connected to the evaporator coil 214 and the condenser 216 via the interconnecting refrigerant tubing 236 forming a refrigerant loop with the receiver tank 230, condenser 216 and reversing valve 234. It is understood that the number and configuration of interconnecting refrigerant tubing 236, receiver tank 230, compressor 232, and reversing valve 234 is exemplary and other configurations are contemplated. FIG. 9 illustrates an exemplary embodiment of the first section 202 having interconnecting refrigerant tubing 236, the receiver tank 230, the compressor 232, and the reversing valve 234.

The first section 202 may also house one or more processor 240 serving as a control unit configured to receive a signal from a sensor, remote controller, or communication device and relaying a signal to the compressor 232. Upon receiving the signal, the compressor 232 circulates refrigerant through the reversing valve 234, receiver tank 230, evaporator coil 214, condenser 216, and an expansion valve, e.g., electronic or thermostatic expansion valve. The expansion valve and the compressor are configured to communicate with the blower system 156 to vary speed depending on call load.

As shown in FIG. 8, a condensate collection system 250 may be positioned adjacent to and under the evaporator coil 214. The condensate collection system 250 may include a condensate pan 252 configured to collect condensation and direct the condensation towards a condensate drain 256. In some embodiments, the condensate pan 252 may be formed similar to a trough and sloped towards the condensate drain 256. In some embodiments, the condensate pan 252 may include multiple condensate drains 256. In some embodiments, the condensate drain 256 may be configured to be attached via a tube to a channel (not shown) formed within the third modular component 14c and into the housing 12 for exiting the HVAC system 10. In some embodiments, a condensate channel may be provided in each modular component 14 such that each condensate channel connects to the adjacent condensate channel of another modular component. For example, each condensate channel may be connected in series such that one end of the condensate channel attaches to the drain in the third modular component 14c and one end of the condensate channel empties at the end 32 of the housing 12 (shown in FIG. 2A) from the first modular component 14a. Referring to FIGS. 2B and 8, in some embodiments, a condensate channel 258 may be provided within one or more side panels 22, 24 and/of 26 of the housing 12 such that tubing connects the condensate drain 256 to the condensate channel 258 within the side panels 22, 24 and/or 26, and the condensate channel 258 empties at the first end 32 of the housing.

FIG. 10 illustrates an optional fourth modular component 14d including an electric heat system 260. In some embodiments, the electric heat system 260 may serve as a secondary source of heating as the modular component 14c may be the primary source of heating as indicated in further detail herein. The electric heat system 260 generally includes a plurality of rods 262 positioned within a first section 263 of the fourth modular component 14d. Each rod 262 supports coil springs 264 that extend over the rod 262. The coil springs 264 are configured to be energized. Generally, air is received from the third modular component 14c and/or the second modular component 14b (shown in FIG. 1) and travels in the direction of the arrow 265 through the plurality of rods 262 supporting the coil springs 264. As the air travels through the rods 262, the coil springs 264 are energized and configured to warm the air to a predetermined temperature. In some embodiments, the rods 262 may be composed of metal (e.g., steel) and formed in a U-shape securing both ends 266 of the rods 262 to a wall 268 separating the first section 263 of the fourth modular component 14d from a second section 270 of the fourth modular component 14d. In some embodiments, the wall 268 may be a fire resistant barrier configured to slow or stop the spread of fire and/or smoke. To that end, the wall 268 may be formed of non-combustible/thermally insulating materials. In some embodiments, each end 266 of the rod may include a threaded groove for fastening to a nut 269 positioned on the wall 268. In some embodiments, each rod 262 may be further secured within the fourth modular component 14d via a wire support 272. A first end 274 of the wire support 272 may be attached to the rod 262, and a second end 276 of the wire support 272 may be attached to the side 54b of the fourth modular component 14d.

A second section 270 of the fourth modular component 14d may also house circuitry, such as one or more processor 280 serving as a control unit configured with hardware/software to receive a signal from a sensor, remote controller, or communication device and provide a signal to an electrical heat strip system 282. The electrical heat strip system 282 may provide power to the coil springs 264 energizing the coil springs 264 and heating the air.

Referring to FIGS. 6B, 7B, 8, and 10-11, the HVAC system 10 may be include circuitry that are able to embody and/or execute the logic of the processes described herein. Logic embodied in the form of software instructions and/or firmware may be executed on any appropriate hardware. For example, logic embodied in the form of software instructions or firmware may be executed on a system or systems, or on a personal computer system, or on a distributed processing computer system, and/or the like. In some embodiments, logic may be implemented in a stand-alone environment operating on a single computer system and/or logic may be implemented in a networked environment, such as a distributed system using multiple computers and/or processors networked together.

In some embodiments, the HVAC system 10 may include one or more processors working to execute processor executable code. For example, the HVAC system 10 may include processors 152, 170, 240, and 280 positioned within the housing 12. Each processor 152, 170, 240, and 280 may be implemented as a single or plurality of processors working together, or independently, to execute the logic as described herein. Exemplary embodiments of the one or more processors 152, 170, 240, 280 may include, but are not limited to, a digital signal processor (DSP), a central processing unit (CPU), a field programmable gate array (FPGA), a microprocessor, a multi-core processor, and/or combinations thereof, for example.

In some embodiments, the one or more processors 152, 170, 240, 280 may transmit and/or receive data via a network 302 to and/or from one or more external systems 300 (e.g., one or more external computer systems, one or more machine learning applications, artificial intelligence, cloud based system, microphones). For example, the one or more processors 152, 170, 240, 280 may allow users of the external systems 300 access via the network 302 to provide and/or receive data. Access methods include, but are not limited to, cloud access and direct download to the one or more processors 152, 170, 240, 280 via the network 302. Additionally, processors 152, 170, 240, 280 may provide data to a user by methods that include, but are not limited to, messages sent through the one or more processors 152, 170, 240, 280 and/or external systems 300, SMS, email, and telephone.

The one or more external systems 300 may be configured to provide information and/or data in a form perceivable to the processors 152, 170, 240, 280. For example, the one or more external systems 300 may include, but are not limited to, implementations as a laptop computer, a smart ring, computer monitor, a screen, a touchscreen, a microphone, a website, a smart phone, a PDA, a cell phone, an optical display, combinations thereof, and/or the like. The external system 300 may provide data in computer readable form, such as a text file, a spreadsheet, a word document, and/or the like.

The one or more processors 152, 170, 240, 280 and the external system 300 may communicate via the network 302. As used herein, the terms “network-based”, “cloud-based”, and any variations thereof, may include the provision of configurable computational resources on demand via interfacing with a computer and/or computer network, with software and/or data at least partially located on a computer and/or computer network, by pooling processing power of two or more networked processors.

The network 302 may be almost any type of network. For example, the network 302 may interface via optical and/or electronic interfaces, and/or may use a plurality of network topographies and/or protocols including, but not limited to, Ethernet, TCP/IP, circuit switched paths, combinations thereof, and the like. For example, in some embodiments, the network 302 may be implemented as the World Wide Web (or Internet), a local area network (LAN), a wide area network (WAN), a metropolitan network, a wireless network, a cellular network, a Global System of Mobile Communications (GSM) network, a code division multiple access (CDMA) network, a 4G network, a 5G network, a satellite network, a radio network, an optical network, an Ethernet network, combinations thereof, and/or the like. Additionally, the network 302 may use a variety of network protocols to permit bi-directional interface and/or communication of data and/or information.

The one or more processors 152, 170, 240, 280 may be capable of reading and/or executing processor executable code and/or capable of creating, manipulating, retrieving, altering and/or storing data structures into one or more memories 304. The one or more processors 152, 170, 240, 280 may include one or more non-transitory memory (e.g., random access memory, read only memory or the like) comprising processor executable code and/or software application. In some embodiments, the one or more memories 304 may be located in the same physical location as the processor 152, 170, 240, 280, for example. Alternatively, one or more memories 304 may be located in a different physical location as the processor and communicate with the processor via a network, such as the network 302. Additionally, one or more memories 304 may be implemented as a “cloud memory” (i.e., one or more memories may be partially or completely based on or accessed using a network, such as network 302).

The one or more memories 304 may store processor executable code and/or information comprising one or more databases and program logic (i.e., computer executable logic). In some embodiments, the processor executable code may be stored as a data structure, such as a database and/or data table, for example. In use, the processor 152, 170, 240, 280 may execute the program logic controlling the reading, manipulation and/or storing of data as detailed in the processes described herein.

The HVAC system 10 may further include one or more sensors 306. The one or more sensors 306 may be configured to monitor one or more physical parameters including pressure, temperature, humidity, vibration, position, force, speed, and the like. The one or more sensors 306 communicate with the processors 152, 170, 240, 280 within the housing 12 to control one or more systems within the HVAC system 10 (e.g., filtration system, blower system, mechanical unit, electrical heat system). Additionally, the one or more sensors 306 may communicate data to the one or more external systems 300 via the network 302. Data provided to the one or more external systems 300 via the network 302 may be used for configuring equipment life, useful life, service life, or operating life of one or more elements within the housing 12, for example.

In some embodiments, each modular component 14 may include a pre-determined time period for installation of the modular component 14 until an act of exchanging the modular component 14 (i.e., swap) is required. At the conclusion of such pre-determined time period, the modular component may be deemed inoperable by internal software of the HVAC system 10. In some embodiments, the HVAC system 10 may prohibit use of the modular component 14 once such pre-determined time period lapses in order to prevent excessive wear and tear on the modular component 14 and/or internal parts of the modular component 14.

In some embodiments, a life table estimate may be determined for each modular component 14 and/or systems within each modular component 14. For example, the life table estimate may include electrical load, equipment life, useful life, service life, and/or operating life for each modular component 14 and/or systems within each modular component 14. Data provided by the processors 152, 170, 240, 280 and/or the one or more sensors 306 to the one or more external systems 300 via the network 302 may be used to determine if the life table estimate has been exceeded or will be exceeded within a predetermined time period. If the life table estimate is exceeded or will be exceeded within a predetermined time period, the processors 152, 170, 240, 280 of the HVAC system 10 and/or the one or more external systems 300 may provide a notification (e.g., e-mail, text, phone call) to the customer and schedule delivery of a replacement modular component 14 prior to failure of the HVAC system 10. For example, if the filtration system 120 within the modular component 14a exceeds the life table (e.g., filter needs replacement), the one or more external systems 300 may provide a notification by e-mail to the customer and schedule delivery of the replacement modular component 14a without the need of a technician. In another example, the one or more sensor 306 may determine that air is not adequately being provided at a predetermined temperature by the HVAC system 10. Processors 152, 170, 240, 280 may provide data to the external system 300. The external system 300 may analyze the data and determine one or more of the systems and/or parts within the HVAC system 10 is not performing or performing at a level capable of providing the predetermined temperature. The external system 300 may provide a notification to the customer of the one or more systems and/or parts within the HVAC system 10 not performing at a level capable of providing the predetermined temperature, the modular component 14 of the one or more systems and/or parts is positioned in, and schedule delivery of a replacement modular component 14.

In some embodiments, the one or more sensors 306 may include wearable user device (e.g., watch, ring). The one or more sensors 306 may be configured to monitor heart rate and/or temperature of the user and provide the data to the one or more processors 152, 170, 240, 280 to adjust temperature of the area of interest accordingly. In some embodiments, the sensors 306 may provide data of the user to the external system 300 (e.g., third party system, application on a mobile device), and the external system 300 may provide the data to the one or more processors 152, 170, 240, 280. For example, a user may have an increase in heart rate and/or temperature from running outside. The one or more sensors 306 may provide the increase in heart rate and/or temperature of the user to the external system 300. The external system 300 may increase air flow within the HVAC system 10 based on the increase in heart rate and/or temperature of the user provided by the one or more sensors 306.

FIG. 12 illustrates an exemplary method 400 for cooling air using the HVAC system 10 in accordance with the present disclosure. In a step 402, circuitry (e.g., the processors 152, 170 and 240) within the HVAC system 10 may receive one or more signals from the one or more external systems 300 and/or the one or more sensors 306 indicating conditioned air is needed. For example, the signal may indicate cooling of air is needed to reach a predetermined temperature within the area of interest 16. In a step 404, the processor 170 may activate the blower system 156 such that air may enter the HVAC system 10 through the return air inlet 42 through each of the modular components 14 and exit the supply air exit 44. In a step 406, the processor 240 may signal the compressor 232 to pump and circulate refrigerant through the reversing valve 234, receiver tank 230, expansion valve, evaporator coil 214, condenser 216, and back to the compressor 232. In a step 408, air provided by the blower system 156 cools as it passes over the evaporator coil 214 and exits the supply air exit 44. In some embodiments, the expansion valve and the compressor 232 may further communicate with the blower system 156 to adjust speed of one or more blower fans 162. In some embodiments, the expansion valve and the compressor 232 may communicate with the blower system 156 via processors 170 and 240. Additionally, one or more freeze sensors may be positioned within the housing 12 or external to the housing 12 and communicate with the blower system 156.

FIG. 12 illustrates an exemplary method 500 for heating air using the HVAC system 10 in accordance with the present disclosure. In a step 502, the processors 152, 170 and 280 may receive one or more signals from the one or more external systems 300 and/or the one or more sensors 306. The signal may indicate heating of air is needed to reach a predetermined temperature with the area of interest 16. In a step 504, the processor 170 may activate the blower system 156 such that air may enter the HVAC system 10 through the return air inlet 42 through each of the modular components 14 and exit the supply air exit 44. In a step 506, the processor 280 may provide a signal to the electrical heat strip system 282 to provide electricity to flow through the coil springs 264. In a step 508, air provided by the blower system 156 over coil springs 264 is heated and the heated air exits the supply air exit 44.

While exemplary embodiments of the inventive concepts have been described for purposed of this disclosure, it will be understood that numerous changes may be made which will readily suggest themselves to those skilled in the art and which are accomplished within the spirit of the inventive concepts disclosed and claimed herein.