Air handler assembly
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Solution Overview
Problem
Conventional air conditioning units are large due to their single-direction airflow design and prone to condensate flooding, requiring substantial space and complicating maintenance, while miniaturized units often fail to efficiently intake air from multiple sides and manage condensate effectively.
Innovation Solution
A miniaturized air handler assembly with opposing coil panels that intake air from multiple sides, using high-velocity airflow to cool air and direct condensate into a drain pan, preventing flooding and allowing for increased BTU capacity and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional single-direction airflow design is used, then air cooling function is provided, but unit size becomes large and requires substantial space
Solution Approach 1:
The patent transitions from single-direction airflow to multi-directional airflow by introducing opposing coil panels that intake air from multiple sides. This dimensional change in airflow pattern allows the system to achieve higher cooling capacity without proportionally increasing unit size, effectively resolving the contradiction between compact size and cooling productivity
Solution Approach 2:
The patent combines multiple cooling functions into a single integrated unit by incorporating opposing coil panels with multiple evaporator coils that simultaneously cool air from different directions. This merging of cooling zones and functions into one compact assembly increases cooling capacity while maintaining a space-efficient design
2Volume of moving object
If miniaturized air handler is designed, then space requirement is reduced, but ability to intake air from multiple sides and manage condensate is compromised
Solution Approach 1:
The patent segments the internal structure by dividing it into distinct zones: a condensate collection zone with a drain pan positioned to receive condensate from all coil panels, and a separate air handling zone. This segmentation allows the miniaturized design to effectively manage condensate from multiple cooling surfaces without compromising reliability
Solution Approach 2:
The drain pan acts as an intermediary element that collects and manages condensate from all opposing coil panels before it can cause flooding. This intermediary structure enables the compact design to handle condensate from multiple sides effectively, preventing reliability issues while maintaining miniaturized dimensions
3Productivity
If larger cooling coil surface area is used to increase BTU capacity, then cooling capacity increases, but unit size and space requirement increase
Solution Approach 1:
The patent achieves increased BTU capacity without proportional increase in cabinet space by utilizing multi-directional airflow through opposing coil panels. This creates effective cooling surface area in multiple spatial dimensions simultaneously, allowing higher productivity within a compact stationary footprint
Solution Approach 2:
The patent nests multiple evaporator coils within the opposing panel structures, creating a compact arrangement where cooling surfaces are efficiently packed. This nested configuration maximizes the cooling coil surface area within the available cabinet space, increasing BTU capacity without requiring additional external space
4Ease of operation
If conventional air handler design is used, then cooling function is provided, but maintenance and changes are difficult due to size
Solution Approach 1:
The patent segments the air handler into modular components including removable coil panels and accessible drain pan sections. This segmentation allows maintenance personnel to access and service individual components without disassembling the entire unit, improving ease of operation while maintaining a compact overall size
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The assembly achieves compact size, high BTU capacity, and efficient airflow without condensate clogging, facilitating easier installation and maintenance, and can be retrofitted into existing HVAC systems.
Implementation Method 1
Heat is removed from the air by the cooling coils and the chilled water within the cooling coils
Implementation Method 2
A fan disposed over the outlet opening, the fan operable to draw air into the enclosed chamber through the coil panels
Implementation Method 3
The high velocity airflow causes condensate to drip, or fall, off the surface of the cooling coils, and into the drain pan
Data Source
AI summary
An air handler assembly provides an air handler that resides completely on a drain pan, and comprises multiple panels. At least two panels join at the edges to form an enclosed chamber with central region. Two of the opposing panels are apertured to enable passage of air. Multiple coils carrying cooling fluid are disposed in a parallel relationship, and on the inner side, of the coil panels. A blower forces high velocity air through one or more opposing coil panels, and across the coils to cool the air. From the coils, cooled air flows to central region of air handler. A fan at the top of the air handler draws the cooled air from an outlet opening that forms in a top panel for dispersing through a duct or plenum.