Compact, high-efficiency air handling unit for residential HVAC systems
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Solution Overview
Problem
Conventional residential HVAC systems have inefficiencies due to standalone optimization of components, leading to suboptimal performance and increased size and noise levels.
Innovation Solution
An air handling unit design featuring a wide-angle vane-diffuser mixed-flow fan system closely coupled with high resistance media (HRMs) placed upstream and downstream of the fan, optimizing the synergetic coupling between components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional forward curved centrifugal fans are used with standalone optimized components, then the system is easier to manufacture and operate, but the efficiency is only about 40 percent and the unit size is larger
Solution Approach 1:
The patent merges the fan, diffuser, and high resistance media into a closely coupled integrated assembly where the fan is positioned immediately adjacent to the media with minimal spacing. This combining of components that were previously optimized separately creates synergistic interactions that improve overall system efficiency to 55% or higher while maintaining manufacturability through modular assembly design.
Solution Approach 2:
The patent changes key geometric parameters including using a mixed-flow fan design with specific blade angles, a diffuser with 15-45 degree angles, and optimizing the spacing between fan blades and media to less than 0.5 inches. These parameter changes enable the system to achieve 55%+ efficiency compared to the 40% efficiency of conventional forward curved fans.
2Device complexity
If conventional air handler designs with spaced components are used, then the device complexity is lower, but the noise level is higher and the unit size is larger
Solution Approach 1:
The patent combines the fan, diffuser, and high resistance media into a tight integrated assembly with minimal spacing between components. This merging reduces the overall unit size by 30-50% and lowers noise levels by approximately 3-10 dB compared to conventional designs, while the modular nature of the integration keeps device complexity manageable.
Solution Approach 2:
The patent implements a nested arrangement where the fan is positioned within the diffuser structure, and the high resistance media are placed in close proximity to both the fan and diffuser. This nesting of components within a compact volume achieves significant size reduction and noise control while maintaining functional independence of each component.
3Ease of manufacture
If components are optimized as standalone elements and then combined, then each component can be manufactured independently, but the overall system performance is suboptimal
Solution Approach 1:
The patent merges previously standalone-optimized components into a closely coupled assembly where the fan, diffuser, and high resistance media interact synergistically. This integration improves system performance to 55%+ efficiency while maintaining ease of manufacture through modular assembly of pre-fabricated components that are designed to work together as an integrated unit.
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
This design enhances efficiency by up to 15% and reduces noise and size by approximately 30-50% compared to conventional systems, while also improving Seasonal Energy Efficiency Ratio (SEER) and reducing parasitic losses.
Implementation Method 1
a mixed-flow fan having a rotor with a plurality of blades to move air from an upstream side of the mixed-flow fan to a downstream side
Implementation Method 2
a wide-angle diffuser having a plurality of vanes coupled to the downstream side of the mixed-flow fan
Data Source
AI summary
An air handler unit for use with residential heating, ventilation, and air conditioning (HVAC) systems. The air handler unit has high resistance mediums (HRMs) coupled closely to a wide-angle vane-diffuser mixed-flow fan system. The HRMs are placed immediately upstream and downstream of the wide-angle vane-diffuser mixed-flow fan to form a closely coupled, compact air handler that provides significant efficiency and noise benefits.