Configurable Air Handler With Hydronic Coil for Defrost-Free Heating
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Solution Overview
Problem
Conventional HVAC systems face challenges in efficiency, space constraints, and adaptability due to changing regulations and consumer demands, requiring customization and increased maintenance costs, especially in high-density apartment complexes where space and mounting locations are limited.
Innovation Solution
A highly configurable air handler system using standardized components with a programmable control circuit that can incorporate a hydronic coil for supplemental heat, eliminating the need for a defrost cycle and allowing flexible installation and maintenance, reducing inventory and labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional HVAC systems are used with separate components for heating and cooling, then the system can provide basic climate control, but the system requires substantial customization for different installation locations and configurations, increasing labor and material costs
Solution Approach 1:
The air handler unit is designed as a universal platform that can be configured for multiple installation types (wall-mounted, floor-standing, closet installation) using the same core components. The standardized housing with adjustable mounting brackets and universal duct connections allows a single design to serve diverse installation locations without customization, directly resolving the contradiction between adaptability and complexity.
2Use of energy by moving object
If highly efficient HVAC systems are used, then energy efficiency is improved, but larger components are required which are antagonistic to limited space availability in high density apartment complexes
Solution Approach 1:
The system combines the air handler, refrigeration coil, and heating elements into a single integrated unit that serves both cooling and heating functions. This merging of previously separate components into one compact platform achieves high energy efficiency through coordinated operation while minimizing the total volume required, allowing installation in space-constrained environments like apartment closets.
Solution Approach 2:
The design nests the refrigeration coil and heating elements within the air handler housing, with components arranged in a space-efficient configuration where smaller elements are positioned within or alongside larger structures. This nesting approach maximizes functional density while minimizing the external dimensions of the unit.
3Reliability
If conventional heat pump systems are used in cold weather, then heating can be provided, but defrost cycles are required which reduce system efficiency and increase maintenance needs
Solution Approach 1:
A hydronic coil system is introduced as an intermediary heating mechanism that works in conjunction with the heat pump. When outdoor temperatures drop below efficient heat pump operation thresholds, the hydronic coil provides supplemental heating without requiring defrost cycles, thereby maintaining heating reliability while eliminating the energy losses associated with defrost operations.
4Ease of manufacture
If standardized components are used throughout the system, then inventory and labor costs are reduced, but flexibility to accommodate different installation parameters may be limited
Solution Approach 1:
The air handler unit incorporates adjustable and reconfigurable elements such as variable mounting bracket positions, rotatable duct connections, and modular component arrangements that can be dynamically adapted to different installation requirements. This dynamic design allows standardized components to achieve flexible configurations without requiring custom manufacturing, simultaneously improving ease of manufacture and adaptability.
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 system enhances energy efficiency, reduces maintenance costs, and extends the life expectancy of HVAC components by using standardized parts, flexible configurations, and programmable control, making it adaptable to various installation parameters and energy sources.
Implementation Method 1
a refrigeration cycle coil and a fan, positioned inside a housing, for moving and conditioning air to and for the space
Implementation Method 2
The air handler subsystem includes a refrigeration cycle coil and a hydronic coil in the air stream
Implementation Method 3
In cold weather, the heat pump works to extract heat from outside atmospheric air (the heat source) and, using a refrigeration process, transfer it to the inside target space (the heat sink)
Data Source
AI summary
The invention relates to an HVAC apparatus, method, and system. Aspects of the invention include a supplemental heat source with an air handler unit for a conventional forced air heating and cooling system. The supplemental heat source in one example is a hydronic subsystem. It can be used alone or to supplement the forced air subsystem. Another aspect of the invention includes an air handling subsystem that has a housing that can be highly flexible in configuration and installation. The housing can support internal components, including a hydronic or other supplemental heat source with the forced air components. At least two sides of the housing can be configured for access for maintenance and repair. A control system can be designed to eliminate need for defrost cycle for forced air refrigeration-type subsystem and/or for better maintenance for comfort in the air conditioned space.