Blower assembly enclosure

Abstract

The invention discloses an air delivery system. The air delivery system includes an enclosure, a panel, and a blower assembly connected to the panel. The enclosure includes a base, a cover having an air vent, and a shield. The shroud has an open shroud top, an open shroud bottom, and an opening defined in the shroud between a first shroud edge and a second shroud edge. Each shroud edge extends between an open shroud top and a shroud bottom. The panel includes a panel opening extending between the first and second shroud edges. The blower assembly includes a blower vent proximate the panel opening, the discharge opening, and an impeller for drawing air through the air port, the panel opening, and the blower vent and driving air out of the vent.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. non-provisional patent application No. 18 / 460,331, filed on September 1, 2023, the entire disclosure of which is incorporated herein by reference in its entirety. Background Art

[0003] The field of the present disclosure relates generally to blower assembly enclosures and, more particularly, to blower assembly enclosures for commercial and residential heat pump water heaters.

[0004] Heat pump water heaters in commercial and residential applications utilize condenser coils to extract heat from the heat pump circulation system and transfer the heat to the water in the water tank. An axial flow fan is positioned at the coil so that ambient air is pushed through the coil and then directed into the HVAC (heating, ventilation and air conditioning / heating, ventilation and air conditioning) ducts. The cooled air can then circulate in the ambient atmosphere or surrounding space. The heat pump system, coil, and axial flow fan are typically placed in an enclosure having a base, a shroud, and a cover. The base has a surface area that is sized to fit over the top surface of the water tank.

[0005] Due to safety regulations, the fan blades of axial flow fans need to be completely enclosed. A wrapped sheet metal shroud is often used to completely surround the axial flow fan and other components of the water heater. Handling the flexible sheet metal that makes up the shroud makes it difficult to repair the water heater. For example, in order to maintain the motor of the axial flow fan, the cover must first be removed before removing the shroud. In addition, fluid or air ducts extending through the cover may also need to be disconnected. The size of the axial flow fan is limited by the size of the enclosure and the size of the base.

[0006] Therefore, it is desirable to provide a heat pump enclosure that is more easily disassembled and allows access to fan components within the enclosure. Summary of the invention

[0007] In one aspect of the present disclosure, an air delivery system is disclosed. The air delivery system includes a housing, a panel, and a blower assembly attached to the panel. The housing includes a base, a cover with an air vent, and a shroud. The shroud has an open shroud top, an open shroud bottom, and an opening defined in the shroud between a first shroud edge and a second shroud edge. Each shroud edge extends between the open shroud top and the shroud bottom. The panel includes a panel opening extending between the first and second shroud edges. The blower assembly includes a blower exhaust port proximate the panel opening, the vent, and an impeller, the impeller being used to draw air through the air vent, the panel opening, and the blower exhaust port and to drive the air out of the exhaust port.

[0008] In another aspect of the present disclosure, a method for assembling an air delivery system is disclosed. The method includes providing a circular base having a top surface, and attaching a shroud to the top surface of the base. The shroud has an open shroud top, an open shroud bottom, and an opening defined in the shroud between a first shroud edge and a second shroud edge. Each shroud edge extends between the open shroud top and the shroud bottom. The method also includes attaching a panel between the first and second shroud edges. The panel includes an external mounting surface and an opening. The method also includes attaching a blower assembly to the external mounting surface of the panel. The blower assembly includes a blower exhaust port proximate to an opening of the panel, a port, and an impeller, the impeller being used to draw air through the air port, the opening of the panel, and the blower exhaust port and to drive the air out of the blower exhaust port. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 shows a perspective view of an air delivery system according to one or more embodiments of the present disclosure;

[0010] Figure 2 Shows from Figure 1 A perspective view of a blower assembly of an air delivery system with the enclosure removed is shown;

[0011] Figure 3 Shows Figure 2 An exploded view of the capsule shown;

[0012] Figure 4 Shows Figure 2 An exploded view of the blower assembly is shown;

[0013] Figure 5 A block diagram showing a method of assembling an air delivery system;

[0014] Figure 6 shows a perspective view of a blower assembly and panel according to an embodiment of the present disclosure;

[0015] Figure 7 Shows Figure 6 An exploded view of the blower assembly shown;

[0016] Figure 8 shows a perspective view of a blower assembly and panel according to an embodiment of the present disclosure;

[0017] Fig. 9 Shows Figure 8 An exploded view of the blower assembly is shown;

[0018] Fig.10 Shows Figure 6 A blower assembly comprising a diffuser plate adjacent to a blower assembly faceplate;

[0019] Fig.11 Shows Fig.10 A blower assembly comprising an alternative embodiment diffuser plate having a centrally disposed diffuser plate opening; and

[0020] Fig.12 Shows Fig.10 A blower assembly includes an alternative embodiment of a diffuser plate having a plurality of openings along the diffuser plate.

[0021] The reference numerals used in the drawings and their meanings are listed in summary form in the list of reference numerals. In principle, identical components are provided with the same reference numerals in the drawings. DETAILED DESCRIPTION

[0022] In the following description and claims, reference will be made to a number of terms which will be defined to have the following meanings.

[0023] As used herein, the singular forms "a", "an", and "the" include plural references unless the context clearly dictates otherwise. The terms "comprising", "including", and "having" are intended to be inclusive and mean that there may be additional elements in addition to the listed elements. The term "optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.

[0024] Embodiments of the present disclosure relate to an air delivery system. The air delivery system includes an enclosure, a panel, and a blower assembly connected to the panel. The enclosure includes a base, a cover with an air vent, and a shroud. The shroud has an open shroud top, an open shroud bottom, and an opening defined in the shroud between a first shroud edge and a second shroud edge. Each shroud edge extends between the open shroud top and the shroud bottom. The panel includes a panel opening extending between the first and second shroud edges. The blower assembly includes a blower exhaust port disposed proximate to the panel opening, the discharge opening, and an impeller, the impeller being used to draw air through the air vent, the panel opening, and the blower exhaust port and to drive the air out of the exhaust port. The shroud includes a rounded shroud body that surrounds a heat pump, or more generally, a component of a heat pump. The blower is outside the shroud so that the blower assembly can be approached for maintenance and service thereof.

[0025] Figure 1 A perspective view of an air delivery system 100 according to one or more embodiments of the present disclosure is shown. The air delivery system 100 includes an enclosure 110 having a base 120, a cover 140, and a shroud 170. The air delivery system 100 also includes a panel 190 and a blower assembly 200 attached to the panel 190. The panel 190 is Figure 2-4 Specifically shown in FIG. Figure 2 A perspective view of air delivery system 100 is shown with blower assembly 200 removed from panel 190 . Figure 3 An exploded view of air delivery system 100 is shown. Components of enclosure 110, including base 120, cover 140, and shroud 170, and in some embodiments, components of panel 190 and blower assembly 200 are typically formed from stamped sheet metal. Stamping or metal pressing processes include bending, crimping, and / or stamping into sheet metal using specialized dies and actuators. As an example, shroud 170 can be formed by a combination of metal rolling and bending. Where applicable, components can be assembled together by crimping, welding, fastening, and / or by interference fit.

[0026] Reference Figures 1 to 3 , the base 120 has a circular base body 122 having a top surface 124. In some embodiments, the base body 122 includes an opening 126 through which a fluid conduit or an electrical conduit can pass. In some embodiments, the base body 122 includes a drain pan 128 for collecting condensation formed on the surface of the enclosure 110. In some embodiments, an evaporator or heat exchanger support 130 extends from the top surface 124 of the base body 122. The support 130 is configured to hold the evaporator or heat exchanger 132. In some embodiments, the top end 134 of the support 130 is flat so that the top end 134 can be attached to the cover 140.

[0027] The cover 140 has a cover body 142 having a bottom surface 144 and a top surface 146. In some embodiments, the cover body 142 includes an opening 148 through which a fluid conduit or an electrical conduit can pass. The cover body 142 also includes an air conduit opening 150 configured as a system inlet. The cover body 142 includes a structure with a rounded edge 154 and a straight edge portion 156. The cover body 142 includes a circumferential sidewall 158 surrounding the structure with a rounded edge 154 and the straight edge portion 156. The circumferential sidewall 158 at the straight edge portion 156 defines a straight edge surface 160 (e.g., Figure 3 In some embodiments, the circumferential sidewall 158 and the straight edge surface 160 are folded or otherwise bent such that the circumferential sidewall 158 and the straight edge surface 160 are perpendicular to the bottom surface 144.

[0028] The shield 170 has a curved elongated body 172 having an open shield top 174 and an open shield bottom 176. The curved elongated body 172 forms an opening 178 (eg, Figure 3170 is generally semicircular such that first and second shield edges 180, 182 extend between an open shield top 174 and an open shield bottom 176 and such that first and second shield edges 180, 182 are opposite and coplanar with each other. In some embodiments, the bend in the elongated body 172 is formed by metal roll bending and the first and second shield edges 180, 182 are folded or otherwise bent such that the first and second shield edges 180, 182 are coplanar.

[0029] like Figure 3 , the panel 190 includes a first surface 192 and a second surface 194 opposite the first surface 192. In some embodiments, the first surface 192 includes tabs 196 configured to hold the air evaporator or heat exchanger 132 and fit between the brackets 130. In some embodiments, the panel 190 includes air openings 198 through which air passes, as explained in further detail below.

[0030] like Figure 2 As shown, the open shield bottom 176 of the shield 170 is removably secured to the top surface 124 of the base 120 such that the coplanar first shield edge 180 and the second shield edge 182 are substantially aligned and coplanar with the drain pan 128 of the base 120. The bottom surface 144 of the cover 140 is removably secured to the open shield top 174 of the shield 170; the bottom surface 144 is Figure 3 As shown in detail in Figure 2 As shown, the rounded edge structure 154 of the cover 140 has the same configuration as the shroud 170 so that they enclose the assembly. The straight edge portion 156 of the cover 140 and the first shroud edge 180 and the second shroud edge 182 of the shroud 170 are substantially coplanar and define the mounting plane 102. In some embodiments, the discharge tray 128 and the first surface 192 of the panel 190 are also coplanar with the straight edge portion 156 of the cover 140 and the first shroud edge 180 and the second shroud edge 182 of the shroud 170. As explained in further detail below, the blower assembly 200 is positioned against the mounting plane 102 so that the blower assembly 200 is connected to at least the panel 190.

[0031] Figure 4 An exploded view of a blower assembly 200 according to an embodiment of the present disclosure is shown. Figure 2 and 4, the blower assembly 200 includes a blower housing 210, a centrifugal impeller 250, and a motor 290. The blower housing 210 includes a first surface 212 and a second surface 214. The blower housing 210 also includes a blower cavity 216 defined by at least one sidewall 218 extending from the second surface 214. The blower cavity 216 is sized and configured to accommodate the impeller 250. The blower cavity 216 also includes an opening 220 through which a shaft (not shown) of the motor 290 passes and is connected to the impeller 250. The blower exhaust port 230 extends from the at least one sidewall 218 and, in some embodiments, is substantially tangential to the at least one sidewall 218. The motor 290 is positioned on an outer surface of the at least one sidewall 218.

[0032] When the blower assembly 200 is assembled for use with the air delivery system 100, the blower housing 210 is connected to the panel 190. The impeller 250 is configured to draw air from the air duct opening 150 of the cover 140 and circulate the air within the enclosure 110. The air is then drawn in through the air opening 198 of the panel 190 and exhausted from the blower exhaust port 230 of the blower assembly 200. Figure 3 The air openings 198 are specifically identified in FIG.

[0033] In some embodiments, the blower housing 210 further includes a bottom cover 222 disposed along a bottom edge 224 of the blower housing 210. The bottom cover 222 protrudes from the second surface 214 so that when the blower assembly 200 is secured to the panel 190, the discharge tray 128 is covered by the blower housing 210.

[0034] The use of a centrifugal impeller 250 instead of an axial fan allows the entire blower assembly 200 to be located externally relative to the enclosure 110 and the shroud 170. This allows the blower assembly 200 to be accessed and serviced without having to remove the shroud 170. Additionally, positioning the motor 290 external to the enclosure 110, shroud 170, and blower housing 210 allows the motor 290 to be accessed and serviced without having to remove the shroud 170, blower housing 210, and blower assembly 200 as a whole.

[0035] Figure 5 A block diagram of a method 300 of assembling an air delivery system is shown. The method includes providing 302 a circular base having a top surface, and attaching 304 a shroud to the top surface of the base. As previously described, the shroud has an open shroud top, an open shroud bottom, and an opening defined in the shroud between a first shroud edge and a second shroud edge. In addition, each shroud edge extends between the open shroud top and the shroud bottom.

[0036] The method 300 also includes attaching 306 a panel between the first and second shroud edges. The panel includes an external mounting surface and an opening. In some embodiments, the method 300 also includes attaching 308 a blower assembly to the external mounting surface of the panel. In some embodiments, the method 300 also includes positioning 310 a cover on the open shroud top. The cover has a structure with a rounded edge and includes a straight edge. To attach 306 the panel, the method 300 also includes attaching 312 the panel to the straight edge of the shroud.

[0037] Figure 6 A perspective view of a blower assembly 400 and a panel 490 is shown in accordance with an embodiment of the present disclosure. Figure 2-4 The blower assembly 200 and the panel 190 , the blower assembly 400 is detachably connected to the panel 490 . Figure 7 An exploded view of a blower assembly 400 is shown in accordance with an embodiment of the present disclosure. Panel 490 includes a first surface 492 and a second surface 494 opposite first surface 492. In some embodiments, first surface 492 includes a sidewall 496. In some embodiments, panel 490 includes an air opening 498.

[0038] The blower assembly 400 includes a blower housing 410, a centrifugal impeller 450, and a motor 499. The blower housing 410 includes an open end 412 and a closed end 414 and at least one sidewall 418 extending between the open end 412 and the closed end 414. The open end 412 and the at least one sidewall 418 define a blower cavity 420. The blower cavity 420 is sized and configured to accommodate the impeller 450. The blower cavity 420 also includes an opening through which the shaft of the motor 499 passes and is coupled to the impeller 450. The motor 499 is positioned on the outer surface of the at least one sidewall. The blower exhaust port 430 extends from the at least one sidewall 418 and, in some embodiments, is substantially tangent to the at least one sidewall 418.

[0039] Similar to Figure 1-4 In the blower assembly 200, the blower housing 410 is detachably attached to the panel 490 by using the attachment member 440. The attachment member 440 extends outward from the open end 412 of the blower housing 410 so that the open end 412 is attached to the panel 490, and the blower cavity 420 is enclosed by the panel 490.

[0040] Figure 8 A perspective view of a blower assembly 500 and a panel 590 is shown in accordance with an embodiment of the present disclosure. Figure 6-7 The blower assembly 400 and the panel 490 , the blower assembly 500 is detachably connected to the panel 590 . Fig. 9An exploded view of a blower assembly 500 is shown in accordance with an embodiment of the present disclosure.

[0041] Fig.10 , 11 12 and 12 show the blower assembly 400 . Fig.10 , 11 Each blower assembly in and 12 includes a respective diffuser 610a, 610b and 610c. Each of diffuser 610a, 610b and 610c is located near panel 492. The diffuser is spaced a distance from the panel. The air sucked into the blower assembly leaves the panel through opening 498 and continues to pass through the diffuser through the opening separating the periphery of the diffuser from the panel. It should be noted that although diffuser 610a, 610b and 610c are used in combination with panel 492, the diffuser can also be used in combination with panel 192. The diffuser and panel can be integral. The one-piece panel and diffuser can be molded by plastic using known manufacturing methods. Alternatively, the diffuser and panel can include discrete components connected or fastened together using conventional fasteners or fastening methods.

[0042] In addition to positioning the diffuser away from the panel to enable air to flow through the gap and past the diffuser plate, the diffuser plate may be provided with openings to increase air flow supplied to the heat pump heat exchanger (not shown). Fig.10 The diffuser plate of does not include openings to enable air to flow through the diffuser plate. In use, the diffuser 610a restricts the air flow to the heat pump heat exchanger to the air passing through the gap between the diffuser plate and the panel. Fig.11 The diffuser plate 610b of 610a includes a plurality of openings or holes 720 located in the middle of the diffuser plate. In use, in addition to the air exiting along the periphery of the diffuser as previously described with respect to the diffuser 610a, additional air may pass through the centrally arranged plurality of openings 720.

[0043] The openings or holes may be located anywhere along the diffuser plate. Fig.12 A diffuser 610c is shown having openings 820 in the middle of the diffuser and along its perimeter. Openings 720 and 820 need not be circular, nor uniform in diameter. Any number, shape, and configuration of openings may be selected to optimize airflow through the apertures to the panel.

[0044] The blower assembly 500 includes a blower housing 510, a centrifugal impeller 550, and a motor 599. The blower housing 510 includes an open end 512 and a removable back plate 514 and at least one side wall 518 extending between the open end 512 and the removable back plate 514. The open end 512, the at least one side wall 518, and the removable back plate 514 define a blower cavity 520. The size of the blower cavity 520 is designed and configured to accommodate the impeller 550. The blower cavity 520 also includes an opening through which the shaft of the motor 599 passes and is coupled to the impeller 550. The motor 599 is positioned on the outer surface of the at least one side wall. The blower exhaust port 530 extends from the at least one side wall 518, and in some embodiments, is substantially tangent to the at least one side wall 518.

[0045] Removable back plate 514 allows access and maintenance of impeller 550 and motor 599 without disassembly Figure 1-4 any other components of enclosure 110 or blower assembly 500 .

[0046] Other variations to the disclosed embodiments may be understood and implemented by those skilled in the art in practicing the claimed invention by studying the drawings, the disclosure and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in a claim should not be construed as limiting the scope of the claim.

[0047] Although the present invention is illustrated and described in detail in the drawings and the foregoing description, such illustration and description are to be considered illustrative or exemplary rather than restrictive. It should be understood, however, that changes and modifications may be made by one of ordinary skill in the art within the scope of the appended claims. In particular, the present invention covers other embodiments having any combination of features from the different embodiments described above and below. In addition, the statements characterizing the present invention made herein relate to one embodiment of the present invention, and not necessarily all embodiments.

[0048] The terms used in the claims should be interpreted as having the widest reasonable interpretation consistent with the foregoing description. For example, the use of the article "one" or "the" when introducing an element should not be interpreted as excluding multiple elements. Similarly, the narration of "or" should be interpreted as inclusive, so that the narration of "A or B" does not exclude "A and B", unless it is clear from the context or the foregoing description that only one of A and B is meant. In addition, the narration of "at least one of A, B and C" should be interpreted as one or more of a group of elements consisting of A, B and C, and should not be interpreted as requiring at least one of each of the listed elements A, B and C, regardless of whether A, B and C are related as categories or otherwise. In addition, the narration of "A, B and / or C" or "at least one of A, B or C" should be interpreted as including any singular entity from the listed elements, such as A, any subset from the listed elements, such as A and B, or the entire list of elements A, B and C.

[0049] This written description uses examples to disclose the invention, including the best mode, and also enables those skilled in the art to practice the invention, including making and using any device or system and performing any combined method. The patent scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. If these other examples have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims, these other examples are intended to be within the scope of the claims.

Claims

1. An air delivery system, comprising: an enclosure including a base, a cover including an air vent, and a shroud having an open shroud top, an open shroud bottom, and an opening defined in the shroud between a first shroud edge and a second shroud edge, each of the first shroud edge and the second shroud edge extending between the open shroud top and the open shroud bottom; a panel including a panel opening, the panel extending between the first shield edge and the second shield edge; and A blower assembly is attached to the panel, the blower assembly including an impeller and a blower housing, the blower housing including a blower exhaust port proximate the panel opening and the impeller, the impeller being configured to draw air through the air port, the panel opening and the blower exhaust port and to force the air out of the blower exhaust port.

2. The air delivery system according to claim 1, wherein: The shield includes a shield body having a rounded shape, and the first shield edge and the second shield edge are arranged opposite to each other.

3. The air delivery system according to claim 2, wherein: The first shield edge and the second shield edge are coplanar.

4. The air delivery system according to claim 1, wherein: The shroud top has a domed outer perimeter comprising a shroud top perimeter, and the cover has a domed outer perimeter defining a cover perimeter, the cover perimeter being substantially the same as the shroud top perimeter.

5. The air delivery system according to claim 4, wherein: A portion of the cover includes a structure with a rounded edge, and a portion of the cover includes a straight edge, wherein the straight edge, the first shield edge, and the second shield edge define a mounting plane.

6. The air delivery system according to claim 5, wherein: The panel is coupled to the straight edge, the first shroud edge, and the second shroud edge along the mounting plane.

7. The air delivery system according to claim 6, wherein: The panel and the shroud together define an interior cavity of the enclosure.

8. The air delivery system according to claim 7, wherein: The blower assembly is located outside the interior cavity of the enclosure.

9. The air delivery system according to claim 1, wherein: The blower assembly further includes a blower housing having at least one sidewall defining a blower cavity.

10. The air delivery system according to claim 9, wherein: The blower exhaust port is defined by the at least one side wall.

11. The air delivery system according to claim 9, wherein: The blower assembly also includes a blower motor having a rotatable shaft coupled to the impeller.

12. The air delivery system of claim 11, wherein: The blower motor is positioned on an exterior surface of the at least one side wall.

13. The air delivery system of claim 9, wherein: The blower housing also includes a housing base that is attached to the panel when the blower assembly is assembled for use in the air delivery system.

14. The air delivery system of claim 1 further comprising a diffuser plate proximate to the panel.

15. The air delivery system of claim 14, wherein: The diffuser plate is positioned at a distance from the panel.

16. The air delivery system of claim 15, wherein: The diffuser plate includes at least one opening.

17. The air delivery system of claim 16, wherein: The diffuser plate includes a plurality of openings.

18. A method of assembling an air delivery system, the method comprising: providing a circular base having a top surface; attaching a shield to the top surface of the base, the shield having an open shield top, an open shield bottom, and an opening defined in the shield between a first shield edge and a second shield edge, each of the first shield edge and the second shield edge extending between the open shield top and the open shield bottom; attaching a panel between the first shroud edge and the second shroud edge, the panel comprising an exterior mounting surface and an opening; as well as A blower assembly is attached to the external mounting surface of the panel, the blower assembly including an impeller and a blower housing, the blower housing including a blower exhaust port proximate to an opening of the panel and the impeller, the impeller being used to draw air through the opening of the panel and the blower exhaust port and to force the air out of the blower exhaust port.

19. The method of claim 18, further comprising positioning a cover over the open shroud top.

20. The method according to claim 19, wherein: The cover has a rounded edge structure and includes a straight edge, wherein attaching the panel further includes attaching the panel to the straight edge.

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