FRAMEWORK FOR AIR HANDLING UNIT

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from and the benefit of India Provisional Application No. 202411057640, entitled “FRAMEWORK FOR AIR HANDLING UNIT,” filed Jul. 30, 2024, which is hereby incorporated by reference in its entirety for all purposes.

BACKGROUND

This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure and are described below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be noted that these statements are to be read in this light, and not as admissions of prior art.

Heating, ventilation, and/or air conditioning (HVAC) systems are utilized in residential, commercial, and industrial environments to control environmental properties, such as temperature and humidity, for occupants of the respective environments. An HVAC system may control the environmental properties through control of a supply air flow delivered to the environment. For example, the HVAC system may place the supply air flow in a heat exchange relationship with another fluid, such as a refrigerant, a chiller fluid, a heated fluid, or other suitable fluid, to condition the supply air flow. In certain embodiments, the HVAC system may be located within an air handling unit (AHU) having a housing or an enclosure, which may include segments, panels, connectors, and so forth that may be assembled to define an interior volume of the HVAC system. Some AHUs may include two tiers separated by structural members and panels that are assembled together to form the enclosure or housing of the AHU. Unfortunately, manufacture of many AHUs, including enclosures of AHUs, may be difficult, expensive, and/or time consuming.

SUMMARY

A summary of certain embodiments disclosed herein is set forth below. It should be noted that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.

In one embodiment, a housing of an air handling unit (AHU) includes a first frame assembly configured to define a first plenum of the AHU, a second frame assembly configured to define a second plenum of the AHU, an intermediate frame assembly configured to be disposed between the first frame assembly and the second frame assembly and configured to directly couple to the first frame assembly and the second frame assembly, and a panel configured to be secured to the intermediate frame assembly. The panel is configured to at least partially separate the first plenum and the second plenum, and the panel includes a first surface configured to be exposed to the first plenum and a second surface configured to be exposed to the second plenum in an assembled configuration of the housing.

In another embodiment, a frame structure of an air handling unit (AHU) housing includes a first frame assembly configured to define a lower tier of the AHU housing, a second frame assembly configured to define an upper tier of the AHU housing, wherein the second frame assembly is configured to be disposed above the first frame assembly, relative to a direction of gravity, and an intermediate frame assembly configured to be disposed between the first frame assembly and the second frame assembly, relative to the direction of gravity. The intermediate frame assembly includes a plurality of intermediate frame segments coupled to one another via a plurality of intermediate frame connectors, and an intermediate frame connector of the plurality of intermediate frame connectors is configured to directly couple to a first frame segment of the first frame assembly and to a second frame segment of the second frame assembly.

In a further embodiment, an intermediate frame assembly of a frame structure for an air handling unit (AHU) housing includes an intermediate frame segment having a first side configured to face an interior of the AHU housing and a second side configured to face an exterior of the AHU housing. The first side includes a flange configured to extend into the interior of the AHU housing, and the second side includes a first recess and a second recess. The intermediate frame assembly also includes an intermediate frame connector configured to be secured to the intermediate frame segment, and the intermediate frame connector is configured to directly couple to a lower tier frame assembly and an upper tier frame assembly of the AHU housing.

DRAWINGS

Various aspects of this disclosure may be better understood upon reading the following detailed description and upon reference to the drawings in which:

FIG. 1 is a perspective view of a building including an embodiment of a heating, ventilating, and air conditioning (HVAC) system, in accordance with an aspect of the present disclosure;

FIG. 2 is a perspective view of an embodiment of an HVAC system having a housing, in accordance with an aspect of the present disclosure;

FIG. 3 is a perspective view of an embodiment of a frame structure of a housing for an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 4 is a perspective view of an embodiment of a frame structure of a housing for an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 5 is an exploded perspective view of a portion of an embodiment of a frame structure of a housing for an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 6 is a perspective view of a portion of an embodiment of a frame segment configured to be incorporated in a frame structure of a housing for an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 7 is an axial view of an embodiment of a frame segment configured to be incorporated in a frame structure of a housing for an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 8 is an exploded axial view of an embodiment of a frame segment configured to be incorporated in a frame structure of a housing for an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 9 is a perspective view of an embodiment of a connector configured to be incorporated in a frame structure of a housing for an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 10 is a perspective view of an embodiment of a connector and a shroud configured to be incorporated in a frame structure of a housing for an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 11 is a detailed perspective view of a portion of an embodiment of a frame structure of a housing for an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 12 is a detailed perspective view of a portion of an embodiment of a frame structure of a housing for an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 13 is an axial view of an embodiment of an intermediate frame segment of a frame structure and a portion of a panel configured to be incorporated in a housing for an HVAC system, in accordance with an aspect of the present disclosure; and

FIG. 14 is a perspective view of a portion of an embodiment of a frame structure of a housing for an HVAC system, in accordance with an aspect of the present disclosure.

DETAILED DESCRIPTION

One or more specific embodiments will be described below. In an effort to provide a concise description of these embodiments, not all features of an actual implementation are described in the specification. It should be noted that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be noted that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be noted that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

As used herein, the terms “approximately,” “generally,” and “substantially,” and so forth, are intended to convey that the property value being described may be within a relatively small range of the property value, as those of ordinary skill would understand. For example, when a property value is described as being “approximately” equal to (or, for example, “substantially similar” to) a given value, this is intended to mean that the property value may be within +/−5%, within +/−4%, within +/−3%, within +/−2%, within +/−1%, or even closer, of the given value. Similarly, when a given feature is described as being “substantially parallel” to another feature, “generally perpendicular” to another feature, and so forth, this is intended to mean that the given feature is within +/−5%, within +/−4%, within +/−3%, within +/−2%, within +/−1%, or even closer, to having the described nature, such as being parallel to another feature, being perpendicular to another feature, and so forth. Further, it should be understood that mathematical terms, such as “planar,” “slope,” “perpendicular,” “parallel,” and so forth are intended to encompass features of surfaces or elements as understood to one of ordinary skill in the relevant art, and should not be rigidly interpreted as might be understood in the mathematical arts. For example, a “planar” surface is intended to encompass a surface that is machined, molded, or otherwise formed to be substantially flat or smooth (within related tolerances) using techniques and tools available to one of ordinary skill in the art. Similarly, a surface having a “slope” is intended to encompass a surface that is machined, molded, or otherwise formed to be oriented at an angle (e.g., incline) with respect to a point of reference using techniques and tools available to one of ordinary skill in the art.

The present disclosure is directed to heating, ventilation, and/or air conditioning (HVAC) systems. HVAC systems may be configured to condition an air flow and to deliver the air flow to a space serviced by the HVAC system to condition the space. As an example, the HVAC system may include a vapor compression circuit configured to circulate a working fluid, cool the working fluid via a condenser, place the cooled working fluid in a heat exchange relationship with the air flow to cool the air flow (e.g., via an evaporator), and deliver the air flow to the space to cool the space. As another example, the HVAC system may be configured to heat the air flow, such as via an electric heating coil, and deliver the air flow to the space to heat the space. Additionally or alternatively, HVAC systems may be configured to place the air flow in a heat exchange relationship with another fluid (e.g., heating fluid, cooling fluid), such as a flow of water.

In some HVAC systems, an air handling unit (AHU) may define one or more air flow paths and may be configured to direct one or more air flows therethrough. The AHU may include one or more air treatment and/or conditioning devices, such as heat exchangers, filters, energy recovery wheels (ERWs), humidifiers, dehumidifiers, and so forth, configured to adjust one or more properties of the air flow to treat and/or condition the air flow for supply to a conditioned space. The AHU may include a housing or an enclosure configured to contain various components and shield the components from an exterior environment, such as an ambient environment. For example, the housing may include a frame structure and panels that cooperatively define an interior volume in which the components may be disposed. However, frame structures of some AHUs are susceptible to various drawbacks. For example, some AHUs may have a frame structure with a tiered configuration defined by a first frame assembly and a second frame assembly that are assembled and secured to one another utilizing various components and/or techniques, such as flanges, fasteners, welding, and so forth. Unfortunately, manufacture and assembly of such frame structures may be complicated, expensive, and/or time-consuming. Additionally, such frame structures may be susceptible to operational inefficiencies, such as inadvertent escape of air, and/or may be aesthetically undesirable.

Thus, it is presently recognized that improvements associated with manufacture and assembly of AHUs are desired. Accordingly, embodiments of the present disclosure are directed to a frame structure of a housing for an AHU that includes connectors (e.g., frame connectors) and segments (e.g., frame segments) configured to couple to one another to form the frame structure and define multiple sections (e.g., plenums) of the housing in an assembled configuration. For example, multiple peripheral frame assemblies defining respective plenums of the housing may be configured to couple with an intermediate frame assembly disposed between the peripheral frame assemblies. In some embodiments, the intermediate frame assembly may include a set of intermediate frame connectors and a set of intermediate frame segments coupled to the set of intermediate connectors. The peripheral frame assemblies may include peripheral frame connectors and peripheral frame segments configured to couple to both the peripheral frame connectors and the intermediate frame connectors.

Each of the intermediate frame segments may have a profile configured to couple to multiple panels (e.g. housing panels) of the housing in an assembled configuration of the frame structure. Additionally, each of the intermediate frame connectors may be configured to couple to multiple intermediate frame segments and multiple peripheral frame segments in the assembled configuration of the frame structure. The arrangement of the intermediate frame assembly between the peripheral frame assemblies may improve manufacture and/or operation of the AHU. For example, as described in further detail below, embodiments of the frame structure disclosed herein may be manufactured and assembled with a reduced number of components (e.g., reduced number of frame segments, reduced number of panels) compared to existing AHUs. Thus, present embodiments of the frame structure may be manufactured and assembled at reduced costs and with reduced labor. Additionally, the disclosed techniques enable manufacture and assembly of AHUs having a tiered configuration in a more cost-effective and time-efficient manner. Present embodiments of the frame structure also enable more efficient operation of AHUs having the frame structure, such as via improved sealing between components of the frame structure. However, it should be noted that frame structures incorporating the present techniques may enable manufacture of an HVAC system (e.g., AHU) having housing sections for enabling any suitable functionality.

Referring now to FIG. 1, a perspective view of a building 10 is shown. The building 10 is served by an embodiment of a heating, ventilating, or air conditioning (HVAC) system 100. The HVAC system 100 may include a plurality of HVAC devices (e.g., heaters, chillers, air handling units [AHUs], pumps, fans, thermal energy storage) configured to provide heating, cooling, air conditioning, ventilation, and/or other services for the building 10. For example, the HVAC system 100 is shown to include a waterside system 120 and an airside system 130. The waterside system 120 may provide a heated or chilled fluid to an air handling unit of the airside system 130. The airside system 130 may use the heated or chilled fluid to heat or cool an air flow provided to the building 10.

The HVAC system 100 is shown to include a chiller 102, a boiler 104, and an air handling unit (AHU) 106 positioned on a roof of the building 10. The waterside system 120 may use the boiler 104 and the chiller 102 to heat or cool a working fluid (e.g., water, glycol) and may circulate the working fluid to the AHU 106. In various embodiments, the HVAC devices of the waterside system 120 can be located in or around the building 10, as shown in FIG. 1, or at an offsite location such as a central plant (e.g., a chiller plant, a steam plant, a heat plant) that serves one or more buildings including the building 10. The working fluid can be heated in the boiler 104 or cooled in the chiller 102, depending on whether heating or cooling is demanded in the building 10. The boiler 104 may add heat to the circulated fluid, for example, by using an electric heating element. The chiller 102 may place the circulated fluid in a heat exchange relationship with another fluid (e.g., a refrigerant) in a heat exchanger (e.g., an evaporator) to absorb heat from the circulated fluid. The working fluid from the chiller 102 and/or the boiler 104 can be transported to the AHU 106 via piping 108.

The AHU 106 may place the working fluid in a heat exchange relationship with an air flow directed through the AHU 106 (e.g., via one or more stages of cooling coils and/or heating coils). The air flow can be, for example, outside air, return air from within the building 10, or a combination of both. The AHU 106 may transfer heat between the air flow and the working fluid to provide heating or cooling for the air flow. For example, the AHU 106 can include one or more fans or blowers configured to force the air flow across or through a heat exchanger containing the working fluid. The working fluid may then return to the chiller 102 or the boiler 104 via piping 110.

The airside system 130 may deliver the air flow supplied by the AHU 106 (e.g., supply air flow) to the building 10 via air supply ducts 112 and may provide return air from the building 10 to the AHU 106 via air return ducts 114. In some embodiments, the airside system 130 includes multiple variable air volume (VAV) units 116. For example, the airside system 130 is shown to include a separate VAV unit 116 on each floor or zone of the building 10. The VAV units 116 can include dampers or other flow control elements that can be operated to control an amount of the supply air flow provided to individual zones of the building 10. In other embodiments, the airside system 130 delivers the supply air flow into one or more zones of the building 10 (e.g., via the supply ducts 112) without using intermediate VAV units 116 or other flow control elements. The AHU 106 can include various sensors (e.g., temperature sensors, pressure sensors) configured to measure attributes of the supply air flow. The AHU 106 may receive input from sensors located within the AHU 106 and/or within the building zone and may adjust the flow rate, temperature, or other attributes of the supply air flow through the AHU 106 to achieve setpoint conditions for the building zone.

It should be appreciated that the AHU 106 may include other configurations while nevertheless incorporating the techniques described herein. For example, some embodiments of the AHU 106 may include one or more heat exchangers configured to circulate a refrigerant (e.g., two-phase fluid) therethrough to enable conditioning (e.g., heating, cooling) of an air flow directed through the AHU 106. Additionally or alternatively, the AHU 106 may include one or more HVAC devices, such as an energy recovery wheel (ERW), a filter, a damper, a blower, a dehumidifier, an electric heating coil, another suitable component, and/or any combination thereof, to enable conditioning and/or treatment of an air flow supplied to the building 10.

With the foregoing in mind, FIG. 2 is a perspective view of an embodiment of an HVAC system 200 that includes a housing or enclosure 202 (e.g., AHU housing, AHU enclosure) having a frame structure 204 (e.g., frame, housing frame, enclosure frame, framework). For example, the HVAC system 200 may be an embodiment of the AHU 106 described above. In the illustrated embodiment, the frame structure 204 includes a first section 206 (e.g., first tier, lower tier, lower section) and a second section 208,(e.g., second tier, upper tier, upper section). Each of the first section 206 and the second section 208 may define a respective interior volume within the housing 202. For example, the first section 206 and the second section 208 may each define a respective plenum and/or a respective portion of an air flow path extending through the housing 202, and the plenums may be fluidly coupled to one another (e.g., within the housing 202) to define the air flow path extending through the housing 202.

The housing 202 may also include a plurality of housing panels 210 coupled to the frame structure 204 and configured to shroud or enclose the interior volumes of the sections 206, 208 from an external (e.g., ambient) environment. For instance, the housing panels 210 may shield the interior volumes from external elements, such as a temperature, precipitation, debris, and so forth. In some embodiments, one or more of the housing panels 210 may include aperture 212 formed therein to enable flow if air into and/or out of the housing 202 (e.g., via ductwork). In this way, the housing 202 may be configured to enable air flow to be directed from the housing 202 toward a conditioned space and/or to be directed from the space into the housing 202. Additionally or alternatively, one or more of the housing panels 210 may include an access panel 214 (e.g., a door, external access panel) formed therein and/or coupled thereto to enable access to an interior of the housing 202 and/or access to components disposed within the housing 202.

In the illustrated embodiment, the second section 208 is disposed above the first section 206 of the housing 202. The frame structure 204 is therefore configured to support the second section 208, as well as components disposed therein, in an assembled configuration of the second section 208 vertically above, relative to a direction of gravity, the first section 206. With the second section 208 coupled to and disposed vertically above the first section 206, the HVAC system 200 (e.g., AHU) may have a tiered configuration. As will be appreciated, the tiered configuration of the HVAC system 200 (e.g., AHU, housing 202) may enable a reduced physical footprint of the housing 202, such that the HVAC system 200 may be installed locations with more limited available space (e.g., external to a building, within a building).

FIG. 3 is a perspective view of an embodiment of the housing 202 illustrating the frame structure 204. In the illustrated embodiment, certain housing panels 210 are not shown in order to illustrate interior volumes of the first section 206 and the second section 208 of the housing 202. To facilitate discussion, the frame structure 204 and its components may be described with reference to a longitudinal axis or direction 220, a vertical axis or direction 222, and a lateral axis or direction 224 with respect to an orientation of the HVAC system 200.

As mentioned above, the first section 206 and the second section 208 may each define a respective interior volume or plenum within the housing 202. For example, the first section 206 may define a first plenum 226, and the second section 208 may define a second plenum 228. The first plenum 226 and the second plenum 228 are at least partially divided or separated via a panel 230 (e.g., partition, interior panel, interior wall, interior partition, interior divider) disposed within the housing 202 (e.g., coupled to the frame structure 204) between the first section 206 and the second section 208. However, the panel 230 may not completely separate the first plenum 226 from the second plenum 228 within the housing 202, such that the first plenum 226 and the second plenum 228 are fluidly coupled to one another within the housing 202. In this way, the first plenum 226 and the second plenum 228 may cooperatively define an air flow path extending through the housing 202. In some embodiments, the panel 230 may at least partially define an opening 232 within the housing 202 that fluidly couples the first plenum 226 and the second plenum 228.

In some applications, the tiered configuration of the HVAC system 200 may be implemented to enable receipt of an air flow by the housing 202 and discharge of an air flow by the housing 202 via common side 234 of the housing 202. For example, the housing 202 may include an air flow inlet 236 (e.g., inlet, plenum inlet) formed in one of the housing panels 210 on the common side 234 of the housing 202 and an air flow outlet 238 (e.g., outlet, plenum outlet) formed in the same housing panel 210 or another housing panel 210 on the common side 234 of the housing 202. In the illustrated embodiment, the air flow inlet 236 may direct air flow into the first plenum 226 of the first section 206, and the air flow outlet 238 may discharge air flow from the second plenum 228 of the second section 208. The air flow inlet 236 is configured to direct air flow into the first plenum 226 and the air flow outlet 238 is configured to discharge air flow from the second plenum 228 along a common axis (e.g., longitudinal axis 220). In some applications, the air flow directed into the first section 206 via the air flow inlet 236 may be directed through first plenum 226, into the second plenum 228 via the opening 232, and out of the housing 202 via the air flow outlet 238. As the air flow is directed through the first plenum 226 and the second plenum 228, the air flow may be directed through and/or across one or more HVAC components disposed within the housing 202 that is configured to adjust a characteristic or property (e.g., temperature, flow rate, pressure, humidity, particulate content) of the air flow before the air flow is discharged from the housing 202. While the illustrated embodiment of the HVAC system 200 includes two tiers (e.g., first section 206, second section 208) other embodiments of the HVAC system 200 may include another number of tiers (e.g., three or more) and/or may include sections arranged in other configurations.

As mentioned above, various components of the HVAC system 200 may be disposed within the housing 202. For example, the first section 206 and/or the second section 208 may contain, and/or enclose components, such as a compressor, a heat exchanger, a blower, a filter, an energy recovery wheel (ERW), another suitable component, or any combination thereof configured to condition an air flow. In the illustrated embodiment, the HVAC system 200 includes a blower assembly 240 (e.g., blower 242, blower motor 244) disposed within the housing 202. More specifically, the blower assembly 240 is disposed within the second plenum 228 of the second section 208. The blower assembly 240 may be configured to direct air flow from the first plenum 226 to the second plenum 228 via the opening 232 and may also draw air flow into the housing 202 via the air flow inlet 236, force air flow out of the housing 202 via the air flow outlet 238, or both. As discussed in further detail below, the frame structure 204 of the housing 202 may be configured to support a weight of components, such as the blower assembly 240, disposed within the housing 202 (e.g., second section 208). Additionally or alternatively, the frame structure 204 may be configured to retain components disposed within the housing 202 in a desired arrangement and/or configuration.

FIG. 4 is a perspective view of an embodiment of the housing 202 illustrating the frame structure 204. In the illustrated embodiment, certain housing panels 210 are not shown in order to illustrate interior volumes of the first section 206 and the second section 208 of the housing 202. The blower assembly 240 illustrated in FIG. 3 is also omitted for clarity.

The frame structure 204 may include an intermediate frame assembly 250 (e.g., intermediate assembly, central raceway assembly, intermediate mullion assembly) configured to couple adjacent peripheral frame assemblies 252 (e.g., tier section frame assemblies, section frame assemblies, frame assemblies, first and second frame assemblies) with one another to define the first section 206, the second section 208, and the housing 202. The intermediate frame assembly 250 may include a first intermediate frame segment or mullion 254 (e.g., first longitudinal frame segment, horizontal frame segment), a second intermediate frame segment or mullion 256 (e.g., first lateral frame segment, horizontal frame segment), a third intermediate frame segment or mullion 258 (e.g., second longitudinal frame segment, horizontal frame segment), and a fourth intermediate frame segment or mullion 260 (e.g., second lateral frame segment, horizontal frame segment). Each of the intermediate frame segments 254, 256, 258, 260 may be configured to couple to one another via intermediate frame connectors 262 (e.g., mullion connectors). That is, the intermediate frame segments 254, 256, 258, 260 may be fastened, secured, or otherwise attached (e.g., directly) to one or more intermediate frame connectors 262. For example, the first intermediate frame segment 254 may be coupled to the second intermediate frame segment 256 via a first intermediate frame connector 262, the second intermediate frame segment 256 may be coupled to the third intermediate frame segment 258 via a second intermediate frame connector 262, the third intermediate frame segment 258 may be coupled to the fourth intermediate frame segment 260 via a third intermediate frame connector 262, and the fourth intermediate frame segment 260 may be coupled to the first intermediate frame segment 254 via a fourth intermediate frame connector 262.

Each of the peripheral frame assemblies 252 may include a plurality of peripheral frame segments or raceways 264 (e.g., frame segments) coupled to one another via peripheral frame connectors 266. The intermediate frame assembly 250 and the peripheral frame assemblies 252 may cooperatively define the first section 206 and the second section 208. In the illustrated embodiment, each of the peripheral frame connectors 266 is coupled to three peripheral frame segments 264 extending crosswise to one another (e.g., along the axes 220, 222, 224). Additionally, each of the intermediate frame connectors 262 is configured to couple to a pair of peripheral frame segments 264 (e.g., extending along the vertical axis 222), such as respective peripheral frame segments 264 partially defining each of the sections 206, 208. In this manner, the intermediate frame assembly 250 may also partially define both the first section 206 and the second section 208.

As described further herein, each of the intermediate frame segments 254, 256, 258, 260, 264 may have a profile (e.g., geometry, configuration) configured to couple to one or more of the housing panels 210. Additionally, in an assembled configuration of the intermediate frame assembly 250, the intermediate frame segments 254, 256, 258, 260 may be configured to cooperatively receive (e.g., accommodate, align with) the panel 230 disposed between the sections 206, 208 to at least partially separate the sections 206, 208 (e.g., plenums 226, 228) from one another. In some embodiments, each of the intermediate frame segments 254, 256, 258, 260 may have a different profile (e.g., geometry, configuration) than that of the peripheral frame segments 264. Such profiles may have features and/or dimensions to facilitate coupling the frame segments 254, 256, 258, 260, 264, the frame connectors 262, 266, and the housing panels 210 with one another.

As the intermediate frame assembly 250 is secured to each peripheral frame assembly 252 (e.g., top frame assembly, bottom frame assembly, first frame assembly, second frame assembly), the intermediate frame assembly 250 may at least partially define each peripheral frame assembly 252. That is, in the illustrated embodiment, the intermediate frame assembly 250 may be a component of both a lower tier frame assembly 268 (e.g., first frame assembly, bottom frame, bottom tier frame assembly) and an upper tier frame assembly 270 (e.g., second frame assembly, top frame, top tier frame assembly). As mentioned above, the intermediate frame connectors 264 are configured to couple (e.g., secure, attach, directly couple) the intermediate frame assembly 250, the lower tier frame assembly 268, and the lower tier frame assembly 268 to one another.

As will be appreciated, other frame structures of AHUs may include a bottom frame assembly having a top horizontal raceway structure and a top frame assembly having a bottom horizontal raceway structure that are coupled to one another in an assembled configuration of the frame structure. However, incorporation of separate, intermediate horizontal raceway structures for top and bottom frame assemblies is associated with various drawbacks that are rectified by the present techniques. For example, incorporation of the intermediate frame assembly 250 (e.g., a single intermediate horizontal raceway structure), which is a common assembly to the lower tier frame assembly 268 and the upper tier frame assembly 270 enables a reduction in the number of components utilized to manufacture and assemble the frame structure 204 of the HVAC system 200. Thus, the frame structure 204 may be manufactured and assembled in a more cost-effective and time-efficient manner. Additionally, the intermediate frame assembly 250 (e.g., single intermediate horizontal raceway structure) enables a reduced number of joints or connections between components that may otherwise be susceptible to inadvertent escape (e.g., leakage) of air flow therethrough. Further, the intermediate frame assembly 250 may enable assembly of the frame structure 204 with greater aesthetic appeal (e.g., reduced number of external components and/or fasteners exposed to an exterior of the frame structure 204 and/or the housing 202).

FIG. 5 is an exploded perspective view of a portion of an embodiment of the frame structure 204 of the housing 202. The illustrated embodiment includes one of the intermediate frame connectors 262 configured to couple to the first intermediate frame segment 254, the second intermediate frame segment 256, and two of the peripheral frame segments 264. In should be appreciated that each intermediate frame connector 262 may be configured to couple (e.g., directly couple) to a respective one of the peripheral frame segments 264 of the lower tier frame assembly 268 (e.g., first frame assembly) and a respective one of the peripheral frame segments 264 of the upper tier frame assembly 270 (e.g., second frame assembly).

The intermediate frame connector 262 may include a bracket 300 that has a first peripheral extension 302 extending from a first end 304 (e.g., bottom end) of the intermediate frame connector 262 and a second peripheral extension 306 extending from a second end 308 (e.g., top end), opposite the first end 304, of the intermediate frame connector 262. The peripheral extensions 302, 306 may be configured to couple to respective peripheral frame segments 264. For example, each of the peripheral frame segments 264 may include (e.g., define) a first opening, space, or passage 310 extending therethrough, and the peripheral extensions 302, 306 may be inserted into the respective first openings 310 of the peripheral frame segments 264. In some embodiments, the peripheral extensions 302, 306 may have a geometry, shape, and/or dimension corresponding to at least a portion of a geometry, shape, or dimension of the peripheral frame segments 264 and/or the first openings 310. Additionally, first holes 312 may be formed through the peripheral extensions 302, 306. In an assembled configuration of the frame structure 204, in which the peripheral extensions 302, 306 are inserted into the first openings 310 of the peripheral frame segments 264, the first holes 312 of the peripheral extensions 302, 306 may align with second holes 314 formed in the peripheral frame segments 264. Mechanical fasteners, such as bolts or rivets, may be inserted through the aligned holes 312, 314 to secure the peripheral extensions 302, 306 and the respective peripheral frame segments 264 to one another. Thus, the mechanical fasteners may fasten the peripheral frame segments 264 to the intermediate frame connector 262.

The bracket 300 of the intermediate frame connector 262 may also include a first intermediate extension 316 extending from a first side 318 (e.g., longitudinal side) of the intermediate frame connector 262 and a second intermediate extension 320 extending from a fourth side 322 (e.g., lateral side) of the intermediate frame connector 262. The first intermediate extension 316 may be configured to couple to the first intermediate frame segment 254, and the second intermediate extension 320 may be configured to couple to the second intermediate frame segment 256. The first intermediate frame segment 254 may form (e.g., define) a second opening, space, or channel 324 (e.g., passage, internal passage, interior volume) extending therethrough, and the first intermediate extension 316 may be inserted into the second opening 324. Additionally, third holes 326 may be formed through the first intermediate extension 316, and fourth holes 328 may be formed through the first intermediate frame segment 254. The third holes 326 and the fourth holes 328 may align with one another in the assembled configuration, and mechanical fasteners may be inserted through the aligned holes 326, 328 to secure the first intermediate frame segment 254 to the intermediate frame connector 262. Furthermore, the second intermediate frame segment 256 may form (e.g., define) a third opening, space, or channel 330 (e.g., passage, internal passage, interior volume) extending therethrough, and the second intermediate extension 320 may be inserted into the third opening 330. Fifth holes 332 may be formed through the second intermediate extension 320, and sixth holes 334 may be formed through the second intermediate frame segment 256. The fifth holes 332 and the sixth holes 334 may align with one another in the assembled configuration, and mechanical fasteners may be inserted through the aligned holes 332, 334 to secure the second intermediate frame segment 256 to the intermediate frame connector 262.

In some embodiments, the intermediate frame connector 262 may include a shroud 336 (e.g., shroud portion, cover portion, cap, stopper) configured to couple to the bracket 300 (e.g., to exterior surfaces of the bracket 300). The shroud 336 may be coupled to the bracket 300 via a mechanical fastener, an adhesive, a punch, a weld, another suitable feature, or any combination thereof. The shroud 336 may be configured to provide a sealing interface for the intermediate frame connector 262. For instance, in the assembled configuration, one or more of the frame segments 254, 256, 264 may be configured to engage the shroud 336. Indeed, respective edges of the frame segments 254, 256, 264 may be configured to abut corresponding edges of the shroud 336. Thus, the shroud 336 may occlude gaps formed between the frame segments 254, 256, 264 and/or the bracket 300 in the assembled configuration, thereby blocking air from flowing between an exterior and an interior of the housing 202. In this way, the shroud 336 may enable the HVAC system 200 to operate more efficiently. Additionally or alternatively, the one or more of the frame segments 254, 256, 264 may be configured to abut the shroud 336 to enable a desired alignment and/or orientation of the frame segments 254, 256, and/or 264 relative to one another, such as during assembly of the frame structure 204. For example, the shroud 336 may limit translation of the peripheral frame segments 264 in a vertical direction (e.g., along vertical axis 222, relative to the bracket 300) to avoid interference with the first intermediate frame segment 254 and/or the second intermediate frame segment 256 that may otherwise be caused by the peripheral frame segments 264 during assembly of the frame structure 204.

Additionally, injection holes 338 may be formed through the bracket 300 and/or the shroud 336. The injection holes 338 may enable material (e.g., foam) to be injected or inserted through the intermediate frame connector 262, and the material may flow from the intermediate frame connector 262 and into the openings 310, 324, 330 to fill the frame segments 254, 256, 264 in the assembled configuration. For example, the material may include an insulating material that limits heat transfer between the interior of the housing 202 and the external environment. Thus, the material may block an impact of a temperature of the external environment on the components disposed within the housing 202 and/or air flow directed through the housing 202 to enable the HVAC system 200 to operate more efficiently.

In the illustrated embodiment, the extensions 302, 306, 316, 320 of the intermediate frame connector 262 are oriented approximately perpendicularly relative to one another. In additional or alternative embodiments, the extensions 302, 306, 316, 320 may be oriented at different angles than depicted, such as at an oblique angle. In further embodiments, the intermediate frame connector 262 may include a different number of extensions 302, 306, 316, 320 than depicted. Further still, although the illustrated intermediate frame connector 262 is configured to couple to the frame segments 254, 256, 264, the intermediate frame connector 262 may be configured to couple to different frame segments, such as to at least one of the intermediate frame segments 258, 260.

In some embodiments, the intermediate frame segments 254, 256, 258, 260 may have a common profile, shape, configuration, and/or geometry. That is, the intermediate frame segments 254, 256, 258, 260 may be of a single embodiment or design. FIG. 6 is a perspective view of a portion of an embodiment of an intermediate frame segment 400 (e.g., horizontal intermediate frame segment), which may be utilized as each of the intermediate frame segments 254, 256, 258, 260 described above. That is, four segments or articles of the intermediate frame segment 400 may be utilized to provide the intermediate frame segments 254, 256, 258, 260. To facilitate discussion, the intermediate frame segment 400 will be described with reference to a longitudinal axis or direction 402, a vertical axis or direction 404, and a lateral axis or direction 406 with respect to an orientation of the intermediate frame segment 400.

The intermediate frame segment 400 may include an interior side 408 (e.g., first side), which may face an interior (e.g., internal volume, plenum) of the housing 202 in the assembled configuration of the frame structure 204. The intermediate frame segment 400 may also include an exterior side 410 (e.g., second side), which may face an exterior of the housing 202 and/or an environment surrounding the housing 202 in the assembled configuration. The intermediate frame segment 400 may further include an upper side 412 (e.g., third side, top side, relative to gravity, relative to vertical axis 404) and a lower side 414 (e.g., fourth side, bottom side, relative to gravity, relative to vertical axis 404).

The exterior side 410 of the intermediate frame segment 400 may include a first exterior extension 416 extending from a first exterior surface 418, a second exterior extension 420 extending from a second exterior surface 422, and a third exterior surface 424 extending from the first exterior extension 416 to the second exterior extension 420. Thus, the first exterior extension 416 to the second exterior extension 420 may offset a third exterior surface 424 from the first exterior surface 418 and the second exterior surface 422. In this manner, the orientation of the exterior extensions 416, 420 relative to the exterior surfaces 418, 422, 424 may form a first exterior recess 426 (e.g., first recess) and a second exterior recess 428 (e.g., second recess) at the exterior side 410 and extending along the longitudinal axis 402 and along opposite vertical ends of the intermediate frame segment 400 (e.g., relative to the vertical axis 404).

In the assembled configuration of the housing 202 and/or HVAC system 200, each of the exterior recesses 426, 428 may be configured to receive at least a portion of a respective one of the housing panels 210. That is, the first exterior recess 426 and the second exterior recess 428 may be configured to receive separate housing panels 210, where the separate housing panels 210 are associated with one of the lower tier frame assembly 268 or the upper tier frame assembly 270. For example, the first exterior recess 426 may be configured to receive a portion of one of the housing panels 210 (e.g., a first housing panel) configured to at least partially enclose the first plenum 226 of the first section 206, and the second exterior recess 428 may be configured to receive a portion of one of the housing panels 210 (e.g., a second housing panel) configured to at least partially enclose the second plenum 228 of the second section 208. In some embodiments, the housing panels 210 may be secured to the intermediate frame segment 400 (e.g., first exterior surface 418, second exterior surface 422) via adhesives applied to the housing panels 210, the first exterior surface 418, and the second exterior surface 422 and/or via fasteners (e.g., bolts, rivets) extending through the housing panels 210, the first exterior surface 418, and/or the second exterior surface 422.

Additionally, a dimension (e.g., linear dimension, vertical dimension) of the third exterior surface 424 extending along the vertical axis 404 from the first exterior extension 416 to the second exterior extension 420 may correspond to (e.g. match) a dimension of the first intermediate extension 316 and/or the second intermediate extension 320 of the bracket 300. In this way, the first intermediate extension 316 and/or the second intermediate extension 320 may be inserted into an opening 430 (e.g., opening 324, 330) defined by the intermediate frame segment 400 and may be captured between the first exterior extension 416 to the second exterior extension 420 to enable assembly of the intermediate frame segment 400 with the bracket 300. Indeed, the third exterior surface 424 may include holes 432 (e.g., holes 328, 334) formed therethrough configured to align with corresponding holes (e.g., holes 326, 332) of the bracket 300 and receive fasteners configured to secure the intermediate frame segment 400 to the bracket 300.

The interior side 408 of the intermediate frame segment 400 may include a first interior extension 434 extending from a first interior surface 436, a second interior extension 438 extending from a second interior surface 440, and a third interior surface 442 extending from the first interior extension 434 to the second interior extension 438. Thus, the first interior extension 434 to the second interior extension 438 may offset a third interior surface 442 from the first interior surface 436 and the second interior surface 440. In some embodiments, the first interior extension 434 may include or define a flange 444 that extends beyond the third interior surface 442 along the lateral axis 406. Thus, in an assembled configuration, the flange 444 may protrude further into an interior of the housing 202. The flange 444 may be configured to enable securement of one or more components disposed within the housing 202 to the intermediate frame assembly 250 having the intermediate frame segment 400. For example, the panel 230 may be secured to the flange 444, as discussed in further detail below. Additionally or alternatively, another component, such as a frame, rail, or base of the blower assembly 240, may be mounted to the flange 444.

As shown, in some embodiments, the first interior extension 434 and/or the flange 444 may have an edge 446 (e.g., longitudinal edge) that is angled obliquely relative to the longitudinal axis 402 and the lateral axis 406. Similarly, the second interior extension 438 may have an edge 448 (e.g., longitudinal edge) that is angled obliquely relative to the longitudinal axis 402 and the lateral axis 406. In an assembled configuration, the edges 446, 448 may be configured to abut corresponding edges 446, 448 of another intermediate frame segment 400 disposed adjacent to the intermediate frame segment 400 and secured to the bracket 300 (e.g., frame connector 262) to which the intermediate frame segment 400 is also secured. In this way, the interior sides 408 of adjacent intermediate frame segments 400 may define a generally uniform (e.g., level, smooth, continuous) surface (e.g., flange 444) to which components, such as the panel 230) may be secured in the assembled configuration.

The upper side 412 of the intermediate frame segment 400 includes an upper surface 450 extending from the second exterior surface 422 to the first interior surface 436. In an assembled configuration, the upper surface 450 may be at least partially captured between the bracket 300 and one of the peripheral frame segments 264 coupled to the bracket 300 and extending vertically above the intermediate frame segment 400 (e.g., along vertical axis 404). Similarly, the lower side 414 of the intermediate frame segment 400 includes a lower surface 452 extending from the first exterior surface 418 to the second interior surface 440, and the lower surface 452 may be captured between the bracket 300 and one of the peripheral frame segments 264 coupled to the bracket 300 and extending vertically below the intermediate frame segment 400 (e.g., along vertical axis 404) in the assembled configuration. Such interfaces between the peripheral frame segments 264 and the intermediate frame segment 400 may block air from flowing between the peripheral frame segments 264 and the intermediate frame segment 400.

The intermediate frame segment 400 may be formed from any suitable material using any suitable manufacturing techniques or methods. For example, the intermediate frame segment 400 may be formed from a metallic material, such as sheet metal. The intermediate frame segment 400 may be formed utilizing a technique such as bending, forming, roll forming, and so forth. In some embodiments, the intermediate frame segment 400 is formed from a single piece of material. In other embodiments, the two or more pieces of material may be cut, punched, or otherwise formed and then secured to eon another to form the intermediate frame segment 400. For example, FIG. 7 is an axial view of an embodiment of the intermediate segment 400 formed from two pieces of material, and FIG. 8 is an exploded axial view of the intermediate segment 400 formed from two pieces of material. The embodiments illustrated in FIGS. 7 and 8 include similar elements and elements numbers as those described above with reference to FIG. 6.

As shown, the intermediate frame segment 400 may be formed via an assembly of a first frame segment section 470 and a second frame segment section 472. Each frame segment section 470, 472 may be individually formed or manufactured utilizing any suitable technique, such as those described herein. The frame segment sections 470, 472 may then be assembled and secured to one another to form the intermediate frame segment 400. In the illustrated embodiment, the first frame segment section 470 generally defines features of the exterior side 410, the upper side 412, and the lower side 414 of the intermediate frame segment 400 described above. The second frame segment section 472 generally defines features of the interior side 408 of the intermediate frame segment 400 described above. However, it should be noted that the first frame segment section 470 also defines the first interior extension 434 and the flange 444. To enable securement of the frame segment sections 470, 472 to one another, one or both of the frame segment sections 470, 472 may include additional features. For example, the second frame segment section 472 includes an interior extension 474, which may abut and be fastened to (e.g., via mechanical fasteners, welding, brazing, adhesive, etc.) the first interior extension 434 and/or the flange 444 of the first frame segment section 470 in an assembled configuration. In some embodiments, the interior extension 474 may reinforce and/or provide additional structural rigidity for the first interior extension 434 and/or the flange 444 to enable improved support of components disposed within the housing 202. Additionally, the first frame segment section 470 includes an internal extension 476, which may abut and be fastened to (e.g., via mechanical fasteners, welding, brazing, adhesive, etc.) the second interior surface 440 of the second frame segment section 472 in an assembled configuration.

FIGS. 9 and 10 are perspective views of an embodiment of the intermediate frame connector 262, in accordance with aspects of the present disclosure. FIGS. 9 and 10 are described concurrently below. The intermediate frame connector 262 includes similar elements and element numbers as those described above with reference to preceding drawings. For example, the intermediate frame connector 262 of the illustrated embodiment includes the bracket 300 having the first peripheral extension 302, the second peripheral extension 306, the first intermediate extension 316, and the second intermediate extension 320. The intermediate frame connector 262 also includes the shroud 336 coupled to the bracket 300. As described above, each of the first peripheral extension 302 and the second peripheral extension 306 is configured to be secured to a respective one of the intermediate frame segments 254, 256, 258, 260 (e.g., horizontal intermediate frame segments, horizontal mullion segments), and each of the first peripheral extension 302 and the second peripheral extension 306 is configured to be secured to a respective one of the peripheral frame segments 264 (e.g., vertical peripheral frame segments, vertical segments). To facilitate discussion, the intermediate frame connector 262 may be described with reference to a longitudinal axis 500, a vertical axis 502, and a lateral axis 504 with respect to an orientation of the intermediate frame connector 262.

The illustrated intermediate frame connector 262 includes the bracket 300 having a first portion 506 and a second portion 508 that generally extend crosswise to one another. The first portion 506 may include the first intermediate extension 316 and may also form a part of the peripheral extensions 302, 306. The second portion 508 may include the second intermediate extension 320 and may also form a part of the peripheral extensions 302, 306. The first holes 312 of the peripheral extensions 302, 306 may be formed in the first portion 506, the second portion 508, or both.

The first portion 506 may include a first base 510 extending along the vertical axis 502. A first end 512 of the first base 510 may form part of the first peripheral extension 302, and a second end 514, opposite the first end 512, of the first base 510 may form part of the second peripheral extension 306. A first support 516 may extend (e.g., along the longitudinal axis 500) from the first base 510 (e.g., a medial section of the first base 510) to form the first intermediate extension 316. Thus, the first base 510 and the first support 516 may collectively define a generally T-shaped geometry. Additionally, first flanges 518 may extend from the first support 516 (e.g., along the lateral axis 504). The first support 516 and the first flanges 518 may be captured by one of the intermediate frame segments 254, 256, 258, 260 (e.g., intermediate frame segment 400) to block movement between the intermediate frame connector 262 and the intermediate frame segment 254, 256, 258, 260. To this end, for example, a dimension 520 (e.g., outer dimension) of the first support 516 and the first flanges 518 (e.g., along the vertical axis 502) may correspond to or match a dimension of the third exterior surface 424 extending from the first exterior extension 416 to the second exterior extension 420 within the opening 430 of the intermediate frame segment 400. The first support 516 and the first flanges 518 may therefore be captured between the first exterior extension 416 to the second exterior extension 420 when the first intermediate extension 316 is positioned within the opening 430 defined by the intermediate frame segment 400 during assembly of the intermediate frame assembly 250. Additionally, one of the injection holes 338 may also be formed through a medial section of the first base 510.

Additionally, the second portion 508 may include a second base 522 extending along the vertical axis 502 (e.g., along the first base 510). The second base 522 may be oriented crosswise to the first base 510. A third end 524 of the second base 522 may form another part of the first peripheral extension 302, and a fourth end 526, opposite the third end 524, may form another part of the second peripheral extension 306. A second support 528 may extend (e.g., along the lateral axis 504) from the second base 522 (e.g., a medial section of the second base 522) to form the second intermediate extension 320. As such, the second base 522 and the second support 528 may collectively define a generally T-shaped geometry. Second flanges 530 may extend from the second support 528 (e.g., along the longitudinal axis 500). Each of the second support 528 and the second flanges 530 may be captured by one of the intermediate frame segments 254, 256, 258, 260 (e.g., intermediate frame segment 400) to block movement between the intermediate frame connector 262 and the intermediate frame segment 254, 256, 258, 260. As similarly described above, a dimension 532 (e.g., outer dimension) of the second support 528 and the second flanges 530 (e.g., along the vertical axis 502) may correspond to or match a dimension of the third exterior surface 424 extending from the first exterior extension 416 to the second exterior extension 420 within the opening 430 of another one of the intermediate frame segments 400. The second support 528 and the second flanges 530 may therefore be captured between the first exterior extension 416 to the second exterior extension 420 when the first intermediate extension 316 is positioned within the opening 430 defined by the another of the intermediate frame segments 400 during assembly of the intermediate frame assembly 250. Another of the injection holes 338 may be formed through a medial section of the second base 522.

In certain embodiments, the portions 506, 508 may be integrally formed with one another. For instance, the portions 506, 508 may be formed from a single piece of material by cutting, bending, extrusion, and/or from multiple material pieces integrally secured to one another by welding or another joining technique. In additional or alternative embodiments, the portions 506, 508 may be separate components that are coupled to one another, such as via mechanical fasteners or adhesives.

The shroud 336 may be coupled to the bracket 300 along exterior surfaces 534 (e.g., surfaces that are exterior relative to an internal angle 536 formed between the bases 510, 522) of the first base 510, the first support 516, the second base 522, and the second support 528. For instance, a mechanical fastener, an adhesive, a weld, a punch, an interference fit, and/or any other suitable feature may be used to couple the shroud 336 to the bracket 300. The shroud 336 also includes tabs 538 configured to limit translation of the peripheral frame segments 264 (e.g., lower tier frame assembly 268, upper tier frame assembly 270) along the vertical axis 502 (e.g., relative to the intermediate frame assembly 250, bracket 300, and/or intermediate frame segments 254, 256, 258, 260), such as during assembly of the frame structure 204. For example, each tab 538 may generally extend in a common direction as that of adjacent flanges 518, 530 and may block abutment between the peripheral frame segments 264 and the adjacent flanges 518, 530 during assembly of the frame structure 204. The illustrated embodiment of FIG. 9 shows tabs 538 disposed between one of the first flanges 518 and the second end 514 of the first base 510 and between one of the second flanges 530 and the fourth end 526 of the second base 522 to limit translation (e.g., toward the flanges 518, 530, along vertical axis 502) of one of the peripheral frame segments 264 extending vertically above the intermediate frame connector 262. However, it should be appreciated that the shroud 336 may also include tabs 538 disposed between one of the first flanges 518 and the first end 512 of the first base 510 and between one of the second flanges 530 and the third end 524 of the second base 522 to limit translation (e.g., toward the flanges 518, 530, along vertical axis 502) of one of the peripheral frame segments 264 extending vertically below the intermediate frame connector 262. In this way, the tabs 538 may enable proper alignment of two intermediate frame segments 254, 256, 258, 260 with the intermediate frame connector 262 and with one another during assembly of the intermediate frame assembly 250. As shown with greater clarity in FIG. 11, in an assembled configuration, each tab 538 may be generally aligned with (e.g., along longitudinal axis 500, along lateral axis 504) and/or disposed within the first exterior recess 426 or the second exterior recess 428 of the corresponding intermediate frame segment 254, 256, 258, 260 to which the tab 538 is adjacent.

FIG. 11 is a perspective view of a portion of an embodiment of the frame structure 204, illustrating two intermediate frame segments 254, 256, 258, 260 (e.g., first intermediate frame segment 254 and second intermediate frame segment 256) in an assembled configuration with the intermediate frame connector 262 and two peripheral frame segments 264 (e.g., vertical peripheral frame segments). To facilitate discussion, the frame structure 204 may be described with reference to a longitudinal axis 550, a vertical axis 552, and a lateral axis 554 with respect to an orientation of the frame structure 204. The illustrated embodiment includes elements and element numbers similar to those described above.

In the assembled configuration, the two peripheral frame segments 264 may abut the shroud 336 of the intermediate frame connector 262. For example, an upper edge 556 of a first peripheral frame segment 558 (e.g., lower peripheral frame segment of first section 206 and/or lower tier frame assembly 268) may abut a lower edge 560 of the shroud 336, and a lower edge 562 of a second peripheral frame segment 564 (e.g., upper peripheral frame segment of second section 208 and/or upper tier frame assembly 270) may abut an upper edge 566 of the shroud 336. Thus, the intermediate frame segment 254 and second intermediate frame segment 256 may extend at least partially between the upper edge 556 of the first peripheral frame segment 558 and the lower edge 562 of the second peripheral frame segment 564 to abut the bracket 300. As mentioned above, one of the tabs 538 of the shroud 336 is generally aligned with the first exterior recess 426 of the first intermediate frame segment 254 (e.g., along the longitudinal axis 550), and another tab 538 of the shroud 336 is generally aligned with the second exterior recess 428 of the first intermediate frame segment 254 (e.g., along the longitudinal axis 550). Additional tabs 538 of the shroud 336 may be respectively aligned with the first exterior recess 426 of the second intermediate frame segment 256 (e.g., along the lateral axis 554) and the second exterior recess 428 of the second intermediate frame segment 256 (e.g., along the lateral axis 554). Further, as shown in the assembled configuration, edges 446 of the respective flanges 444 of the first intermediate frame segment 254 and the second intermediate frame segment 256 abut one another. In this way, the respective flanges 444 of the intermediate frame segments 254, 256, 258, 260 may define a generally uniform, continuous, and/or even surface to which components, such as the panel 230, may be secured.

FIG. 12 is a perspective view of a portion of an embodiment of the frame structure 204 illustrating the first intermediate frame segment 254 and the second intermediate frame segment 256 in an assembled configuration with the intermediate frame connector 262, the first peripheral frame segment 558, and the second peripheral frame segment 564 (e.g., vertical peripheral frame segments). The illustrated embodiment includes elements and element numbers similar to those described above, and the frame structure 204 may be described with reference to the longitudinal axis 550, the vertical axis 552, and the lateral axis 554 with respect to an orientation of the frame structure 204.

In the illustrated embodiment, the first intermediate frame segment 254 and the second intermediate frame segment 256 each include the first frame segment section 470 with the second frame segment section 472 omitted to illustrate engagement between the first intermediate frame segment 254, the second intermediate frame segment 256, and the bracket 300. As similarly described above, the first support 516 and the first flanges 518 of the bracket 300 extend within the opening 430 defined by the first intermediate frame segment 254 and are captured (e.g., along vertical axis 552) between the first exterior extension 416 and the second exterior extension 420 of the first intermediate frame segment 254. Similarly, the second support 528 and the second flanges 530 of the bracket 300 extend within the opening 430 defined by the second intermediate frame segment 256 and are captured (e.g., along vertical axis 552) between the first exterior extension 416 and the second exterior extension 420 of the second intermediate frame segment 256. In this way, the features of the first intermediate frame segment 254, the second intermediate frame segment 256, and the bracket 300 enable desired alignment and securement of the components of the frame structure 204 (e.g., intermediate frame assembly 250) during assembly of the frame structure 204. Further, as shown in the illustrated embodiment, the injection holes 338 are fluidly coupled to the respective openings 430 defined by the first intermediate frame segment 254 and the second intermediate frame segment 256 to enable injection of material (e.g., foam material) within the openings 430 after assembly of the frame structure 204.

FIG. 13 is an axial view of an embodiment of the intermediate frame segment 400 coupled to a portion of the panel 230 configured to be disposed between the first section 206 and the second section 208 of the housing 202. The illustrated embodiment includes similar elements and elements numbers as those described above with reference to preceding drawings.

As discussed above, present embodiments include the intermediate frame assembly 250 configured to be incorporated as a common component or assembly of the lower tier frame assembly 268 and the upper tier frame assembly 270 of an air handling unit having a tiered configuration. Thus, the lower tier frame assembly 268 does not include a separate upper horizontal raceway structure that is mechanical attached to a separate lower horizontal raceway structure of the upper tier frame assembly 270. In this way, the present techniques enable a substantial reduction in number of components, which decreases costs and labor associated with manufacture and assembly of the frame structure 204 of the AHU.

As will be appreciated, other AHUs having upper and lower tier frame assemblies with separate components (e.g. horizontal raceway structures) that are mechanical fastened to one another during assembly may also include other separate or dedicated components. For example, other AHUs having separate upper and lower tier frame assemblies may also include separate panels (e.g., divider panels) to enclose the respective tiers or frame assemblies. Present embodiments, on the other hand, include a single panel (e.g., panel 230) disposed between the first section 206 (e.g., lower tier) and the second section 208 (e.g., upper tier) in an assembled configuration of the housing 202. Thus, the present techniques enable a further reduction in components utilized to assemble and provide the AHU (e.g., HVAC system 200, housing 202) having a tiered configuration with the first section 206 and the second section 208.

The panel 230 may be incorporated in the housing 202 with the frame structure 204 to at least partially divide the first plenum 226 extending through the first section 206 and the second plenum 228 extending through the second section 208. For example, the panel 230 may be coupled to one or more of the intermediate frame segments 254, 256, 258, 260 (e.g., intermediate frame segments 400) assembled to form the intermediate frame assembly 250. In the illustrated embodiment, the panel 230 includes a generally box-shaped structure having an upper section 600 (e.g., sheet, layer, panel, pane), a lower section 602, and one or more side sections 604. The lower section 602 may be or include a first surface exposed to the first plenum 226 defined within the housing 202, and the upper section 600 may be or include a second surface exposed to the second plenum 228 within the housing 202 in an assembled configuration of the housing 202 (e.g., HVAC system 200). The upper section 600, lower section 602, and one or more side sections 604 may generally define a rectangular prism. In some embodiments, the panel 230 may define a generally enclosed inner volume 606. In an assembled configuration of the panel 230 with the intermediate frame segment 400, the upper section 600 of the panel 230 may be secured to the flange 444 and/or the interior extension 474 of the intermediate frame segment 400, such as via mechanical fasteners, welding, brazing, adhesives, another suitable joining technique, or any combination thereof. The panel 230 may also include a lower extension 608 that extends (e.g., outwardly from the side section 604, relative to inner volume 606) from the lower section 602. The lower extension 608 may be secured to the second interior extension 438 of the intermediate frame segment 400, such as via mechanical fasteners, welding, brazing, adhesives, another suitable joining technique, or any combination thereof. It should be appreciated that the panel 230 may be coupled to any combination of the intermediate frame segments 254, 256, 258, 260 in a similar or other suitable manner. In this way, the intermediate frame assembly 250 is configured to support the panel 230 at least partially dividing the first plenum 226 extending through the first section 206 and the second plenum 228 extending through the second section 208 within the housing 202.

In some embodiments, one or more of the intermediate frame segments 254, 256, 258, 260 may also be configured to support other components disposed within the housing 202. For example, FIG. 14 is a perspective view of a portion of an embodiment of the frame structure 204 (e.g., intermediate frame assembly 250), illustrating an embodiment of the intermediate frame segment 400 supporting HVAC equipment 620 (e.g., blower assembly 240, heat exchanger, heater, filter, ERW, etc.) disposed within the housing 202. For example, the HVAC equipment 620 may include a support rail 622 of the blower assembly 240 described above. The HVAC equipment 620 may be mounted to one or more respective flanges 444 of the intermediate frame segments 254, 256, 258, 260, which are configured to support a weight of the HVAC equipment 620.

As described in detail herein, embodiments of the present disclosure are directed to a frame structure of a housing for an AHU that includes connectors (e.g., frame connectors) and segments (e.g., frame segments) configured to couple to one another to form the frame structure and define multiple sections (e.g., plenums) of the housing in an assembled configuration. Multiple peripheral frame assemblies defining respective plenums of the housing may be configured to couple with an intermediate frame assembly disposed between the peripheral frame assemblies. In some embodiments, the intermediate frame assembly may include a set of intermediate frame connectors and a set of intermediate frame segments coupled to the set of intermediate connectors. The peripheral frame assemblies may include peripheral frame connectors and peripheral frame segments configured to couple to both the peripheral frame connectors and the intermediate frame connectors. Each of the intermediate frame segments may have a profile configured to couple to multiple panels (e.g. housing panels) of the housing in an assembled configuration of the frame structure. Additionally, each of the intermediate frame connectors may be configured to couple to multiple intermediate frame segments and multiple peripheral frame segments in the assembled configuration of the frame structure. The arrangement of the intermediate frame assembly between the peripheral frame assemblies improve manufacture and/or operation of the AHU. For example, embodiments of the frame structure disclosed herein may be manufactured and assembled with a reduced number of components (e.g., reduced number of frame segments, reduced number of panels) compared to existing AHUs. Thus, present embodiments of the frame structure may be manufactured and assembled at reduced costs and with reduced labor. Additionally, the disclosed techniques enable manufacture and assembly of AHUs having a tiered configuration in a more cost-effective and time-efficient manner. Present embodiments of the frame structure also enable more efficient operation of AHUs having the frame structure, such as via improved sealing between components of the frame structure.

While only certain features and embodiments have been illustrated and described, many modifications and changes may occur to those skilled in the art, such as variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, such as temperatures and pressures, mounting arrangements, use of materials, colors, orientations, and so forth, without materially departing from the novel teachings and advantages of the subject matter recited in the claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the disclosure.

Furthermore, in an effort to provide a concise description of the exemplary embodiments, all features of an actual implementation may not have been described, such as those unrelated to the presently contemplated best mode, or those unrelated to enablement. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation specific decisions may be made. Such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure, without undue experimentation.

The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function]. . . ” or “step for [perform]ing [a function]. . . ”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).