Air Handler U-Bend Housing Design to Reduce Reverse Flow and Noise

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Solution Overview

Problem

Modern air handler devices rely on outdated structural designs, leading to inefficiencies such as reverse flow, increased noise, and higher operating costs due to inadequate aerodynamic and acoustical performance.

Innovation Solution

The introduction of improved designs featuring a U-bend structure, rounded corners, and optimized flow channels within air handler devices to reduce reverse flow, noise, and energy losses, while also incorporating thermal transfer units for simultaneous heating and cooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional structural designs are used in air handler devices, then device simplicity is maintained, but reverse flow occurs and aerodynamic performance deteriorates

Engineering Contradiction:

Improveaerodynamic performanceVSAvoidstructural design complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent applies rounded corners and curved transitions in the housing and flow channels instead of sharp angles and straight lines. This curvature design reduces flow separation and reverse flow, improving aerodynamic performance while managing the complexity through systematic application of curved geometry throughout the device structure.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Object-affected harmful factors

If conventional flow channels are used, then manufacturing simplicity is maintained, but noise levels increase due to poor aerodynamic performance

Engineering Contradiction:

Improvenoise levelVSAvoidflow channel manufacturing

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The flow channels incorporate rounded corners and smooth curved transitions throughout their length. This curvature eliminates sharp angles that cause flow separation and turbulence, thereby reducing noise generation. The manufacturing complexity is managed through consistent application of curved geometry that can be achieved through standard forming processes.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Power

If conventional housing designs are used, then device simplicity is maintained, but fan horsepower requirements increase due to reverse flow

Engineering Contradiction:

Improvefan horsepowerVSAvoidhousing design

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The housing design features rounded corners at all internal angles and curved transitions between different housing sections. This eliminates flow separation and reverse flow that would otherwise increase pressure losses and require higher fan horsepower. The systematic application of curved geometry throughout the housing manages complexity while delivering significant power efficiency improvements.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Loss of energy

If conventional duct interfaces are used, then installation simplicity is maintained, but reverse flow at corners increases energy losses

Engineering Contradiction:

Improveenergy loss at duct cornersVSAvoidduct connection simplicity

Core Design Contradiction:

Loss of energyVSEase of operation

Solution Approach 1:

The duct interfaces incorporate rounded corners instead of sharp angles, which eliminates flow separation and reverse flow at the duct-housing junctions. This curved geometry design reduces energy losses while maintaining straightforward connection procedures through standardized rounded interface geometries that simplify alignment and sealing.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 solutions result in reduced fan horsepower, quieter operation, longer motor life, and lower operational costs by enhancing aerodynamic and acoustical performance, allowing for efficient air handling and temperature control within defined height constraints.

Implementation Method 1

At second side, the housing can have a rounded corner determined to mitigate a reverse flow of the fluid at corners of the duct

Methodology Applied

Scientific EffectAerodynamic flow control: Flow Separation

Implementation Method 2

The outer surface can be sloped, causing the flow of the fluid entering the intake duct in the radial direction to change to the direction along the longitudinal axis

Methodology Applied

Scientific EffectFlow direction change: Flow Separation

Implementation Method 3

The plurality of thermal transfer units can be respectively situated in different ones of the plurality of duct interfaces

Methodology Applied

Scientific EffectThermal transfer: Conduction (thermal)

Implementation Method 4

configured to heat a first air flow concurrently with the second thermal transfer unit cooling a second air flow

Methodology Applied

Scientific EffectHeat exchange: Convection

Data Source

PatentUS11846434B2Air handler devices with U-bend design

Publication Date: 2023.12.19 BEST TECHNOLOGIES INC

AI summary

Architectures and techniques are presented that can facilitate improved design and function of certain air handler devices. Architectures directed to an improved air handler device can be designed to improve temperature control demands such as, e.g., concurrently heat and cool air and reducing device dimensions (e.g., size, weight) that can reduce costs and mitigate shipping and installation difficulties. Architectures directed to U-bend structures can further reduce footprint on leasable space and provide improved acoustics, service access, and reduced energy consumption and infrastructure costs.