Fan Cube Array Structure for Air-Handling Systems

Description

RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 63/713,563, filed Oct. 29, 2024, the content of which is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to air-handling systems and, more particularly, to fan array structures for air-handling systems.

BACKGROUND OF THE INVENTION

Air-handling systems are utilized to move air according to desired ventilation parameters for the environment of the system. The air-handling systems can be designed to provide desired volumetric flow rates and desired pressures for a specific environment. Air handling systems are used in almost every commercial and industrial facility. Air handling systems include components configured to work together to condition air as part of a primary ventilation system for facilities.

Air-handling systems can utilize one or more fan arrays formed from multiple individual fans to move the air instead of a single fan structure. The individual fans (and their corresponding assemblies) form a fan array and work in parallel to generate the required output from that fan array. Air handling loads, e.g., heating and cooling loads, as well as circulation requirements generally, vary based on the type, size and location of a facility, occupation, use and the like. As such, air handling systems are custom designed for each individual facility.

Fan assemblies, which may include the fan, motor, shrouds and any supports required for installation, are installed within large metal (e.g., steel) grid structures. To construct a fan array, these fan assemblies, formed of individual cubes, are stacked on top of and next to each other (or side-by-side). These assemblies are large and heavy and may require that a building structure is redesigned or reinforced to meet building codes in the event of retrofit design.

Accordingly, there is a need for a lighter weight, smaller footprint fan array that reduces the required material, assembly time, and associated costs.

SUMMARY OF THE INVENTION

Aspects of this disclosure relate to a fan array structure for housing two or more fan assemblies. For example, the fan array structure may comprise a two-by-two (2×2) fan array that holds four fan assemblies. However, any sized array may be used. For example, in various embodiments, the fan array structure may comprise two or more cubes for housing fan assemblies in an array constructed using a panel system including a plurality of panels connected at corner brackets. In various embodiments, various components of the fan array structure (including the plurality of panels and corner brackets) are connected using blind rivets. In various embodiments, each of the two or more cubes may have an open front and an open back, include a fan support, and be configured to house a single fan assembly. The plurality of panels define the top wall, the bottom wall, the left side wall, and the right side wall of each of the two or more cubes. In various embodiments, at least one panel wall is shared by two or more cubes within the fan cube array. For example, at least one panel may define both a top wall of one cube and a bottom wall of another cube or both a left side wall of one cube and a right side wall of another cube.

In various embodiments, panels may run the length of two or more cubes such that a single panel can support multiple cubes. For example, the plurality of panels may include first panels and second panels, the first panels having a first length equal to a length of two or more cubes, and the second panels having a second length equal to a length of a single cube. In such embodiments, the first panels may define vertical panel walls within the fan array structure, and the second panels may define horizontal panel walls within the fan array structure, such that at least one of the first panels may define both a side wall of a first cube and the same side wall of a second cube. Alternatively, the first panels may define horizontal panel walls within the fan array structure, and the second panels may define vertical panel walls within the fan array structure, such that at least one of the first panels may define both the top wall (or the bottom wall) of a first cube and the top wall (or the bottom wall) of a second cube.

These and other objects, features, and characteristics of the systems and/or methods disclosed herein, as well as the methods of operation and functions of the related elements of structure and the combination thereof, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawing, all of which form a part of this specification. It is to be expressly understood, however, that the drawing is for the purpose of illustration and description only and is not intended as a definition of the limits of the invention. As used in the specification and in the claims, the singular form of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is illustrated by way of example and not limited in the accompanying figure in which like reference numerals indicate similar elements and in which:

FIG. 1 depicts a perspective view of an example fan cube array structure, according to one or more aspects described herein.

This drawing is provided for purposes of illustration only and merely depicts a typical or example embodiment. This drawing is provided to facilitate the reader's understanding and shall not be considered limiting of the breadth, scope, or applicability of the disclosure. For clarity and ease of illustration, this drawing is not necessarily drawn to scale.

DETAILED DESCRIPTION

In the following description of various examples of the invention, reference is made to the accompanying drawing, which forms a part hereof, and in which are shown by way of illustration various example structures, systems, and steps in which aspects of the invention may be practiced. It is to be understood that other specific arrangements of parts, structures, example devices, systems, and steps may be utilized, and structural and functional modifications may be made without departing from the scope of the present invention. Also, while the terms “top,” “bottom,” “front,” “back,” “side,” and the like may be used in this specification to describe various example features and elements of the invention, these terms are used herein as a matter of convenience, e.g., based on the example orientations shown in the figure. Nothing in this specification should be construed as requiring a specific three-dimensional orientation of structures in order to fall within the scope of this invention.

Air-handling systems include, among other components, one or more fan motor assemblies in an array to generate the required airflow for the environment of the air-handling system. The invention described herein relates to a fan cube array structure of minimalistic design that holds fan (motor) assemblies within an air handling system or for stand-alone operation. For example, FIG. 1 depicts a perspective view of an example fan cube array 100, according to one or more aspects described herein. As depicted in FIG. 1, fan cube array 100 may comprise a two-by-two (2×2) fan array that holds four fan assemblies. For example, the four fan assemblies may each comprise an 18″ fan-motor assembly. However, as will be appreciated based on the disclosure included herein, the size of the array 100 can and will vary based on the air handling requirements (e.g., heating and cooling) for the facility and location, the space, for example, the footprint allowed for the air handling system, and other considerations. For example, it will be appreciated that fan cube array 100 can include fan assemblies in an array of X by Y, where X and Y are at least 1. In various embodiments, X or Y is at least 2. In various embodiments, fan cube array 100 may be part of a larger air handling system that includes, for example, heaters, coolers/chillers, and other environmental control equipment.

In various embodiments, fan cube array 100 may comprise one or more shared panel walls 120, one or more fan supports 140, one or more corner brackets 160, and/or one or more other components. In various embodiments, fan cube array 100 may comprise one or more shared panel walls 120 and/or one or more other panel walls. For example, unlike conventional fan cube array designs, fan cube array 100 may comprise a panel system constructed of one or more shared panel walls 120 having a length supporting (or corresponding to) two or more fan assemblies (or cubes) and/or one or more other panel walls having a length supporting (or corresponding to) a single fan assembly (or cube). In this way, fan cube array 100 amounts to a shared structural system requiring reduced material and associated cost and weight.

In various embodiments, each of the cubes is of substantially equal height and width. In other embodiments, the cubes are each a uniform height and a uniform width, with the uniform height being different than the uniform width. In such embodiments, the length supporting (or corresponding to) two or more fan assemblies (or cubes) and the length supporting (or corresponding to) a single fan assembly (or cube) are based on the uniform height or the uniform width of the fan assemblies (or cubes), respectively.

In various embodiments, the one or more components of fan cube array 100 may be composed of sheet metal, square tubing, and/or one or more other parts. For example, the one or more shared walls 120 (and any of one or more other panel walls), the one or more fan supports 140, the one or more corner brackets 160, and/or one or more other components may be composed of sheet metal, square tubing, and/or other component parts. In some embodiments, such metal sheets may be punched using a punching machine and/or bent using a bench press. In some embodiments, the square tubing may be cut using a band saw and/or drilled using a computer numerical control (CNC) milling machine. In some embodiments, the square tubing may be flow-drilled (e.g., using a CNC milling machine). Flow drilling refers to the extrusion of material when drilling using friction in order to thread the extruded portion, resulting in a stronger bolted connection. Using flow-drilled square tubing in fan cube array 100 may produce a lighter and sturdier structure. In some embodiments, rivets may be used to hold the components together (e.g., instead of flow drilling). For example, the structure may be held together with heavy-duty structural rivets (such as blind rivets), which include a body and a mandrel that locks into place during installation, creating a secure, vibration-resistant joint. The lack of threads in such fasteners relieves the user of dealing with torquing and torque relaxation, which is a major issue especially for applications with consistent vibration. Using rivets in this manner results in a sturdy structure that is easy to install and maintain.

In various embodiments, each of the one or more components of fan cube array 100 may be constructed of aluminum, steel, stainless steel, and/or one or more other materials. For example, the rivets may come in galvanized and stainless steel form, suitable for multiple applications.

In an example embodiment, fan cube array 100 may measure (in terms of length-width-height) in a range from 26 inches by 33 inches by 33 inches (holding a 15 inch fan in each cube) to 1222 inches by 612 inches by 82 inches (holding a 60 inch fan in each cube in a 5×10 array of 50 cubes). In some such (or other) embodiments, the pressure may be in a range between 3 in. w.g. to 12 in. w.g.

The fan cube array structure described herein and having at least one panel wall that is shared by two or more cubes within the fan cube array may eliminate unnecessary material, provide for a sturdier structure, and simplified assembly, while also maintaining the acoustic and operational performance of conventional fan cube array designs. The fan cube array structure described herein may also require reduced labor time due at least in part to the reduced number of sub-assemblies and parts overall required to assemble the fan cube array structure.

It is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth herein. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Variations and modifications of the foregoing are within the scope of the present invention. It should be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawing. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention.

While the preferred embodiments of the invention have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made therein without departing from the spirit of the invention, the scope of which is defined by this description.

Reference in this specification to “one embodiment”, “an embodiment”, “some embodiments”, “various embodiments”, “certain embodiments”, “other embodiments”, “one series of embodiments”, or the like means that a particular feature, design, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. The appearances of, for example, the phrase “in one embodiment” or “in an embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, whether or not there is express reference to an “embodiment” or the like, various features are described, which may be variously combined and included in some embodiments, but also variously omitted in other embodiments. Similarly, various features are described that may be preferences or requirements for some embodiments, but not other embodiments.

The language used herein has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter. Other embodiments, uses and advantages of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. The specification should be considered exemplary only, and the scope of the invention is accordingly intended to be limited only by the following claims.