Movable Damper Air Control Module for HVAC Load Matching

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Solution Overview

Problem

Conventional HVAC units are over-rated for most of the year, leading to inefficient electric power consumption, noise, and reduced operational efficiency due to intermittent operation and suboptimal motor efficiency.

Innovation Solution

A mechanically modulated air control module with a movable damper blade is used to restrict airflow, allowing for processor-controlled adjustment of electric current consumption by the blower motor, optimizing power usage and reducing noise.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the HVAC unit is over-rated to handle the largest expected load, then the heating or cooling capacity is sufficient, but the electric power consumption is inefficient for most of the year

Engineering Contradiction:

Improveheating or cooling capacityVSAvoidelectric power consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent applies dynamics by making the damper blade movable and adjustable to different positions. The blade can be dynamically repositioned to restrict or allow airflow through the HVAC unit, enabling the system to adapt its operation to match varying actual loads throughout the year, thereby reducing electric power consumption while maintaining sufficient heating or cooling capacity.

Inventive Principle:

Principle #15Dynamics

2Reliability

If the blower and compressor are over-rated, then the HVAC unit can handle peak loads, but the unit only needs to run part time at full capacity, reducing operational efficiency

Engineering Contradiction:

Improvepeak load handling capabilityVSAvoidoperational efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent implements continuity of useful action by enabling the HVAC unit to operate continuously at partially restricted airflow rather than cycling on and off. The movable damper blade allows the system to maintain continuous operation at reduced capacity, eliminating the inefficiencies of intermittent start-stop cycles and improving overall operational efficiency while maintaining peak load handling capability.

Inventive Principle:

Principle #20Continuity of useful action

3Use of energy by moving object

If the HVAC unit operates with intermittent start-and-stop cycles, then the electric power consumption is reduced, but mechanical, electrical, and thermal transients reduce the operative lifetime

Engineering Contradiction:

Improveelectric power consumptionVSAvoidoperative lifetime

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The patent eliminates intermittent cycling by enabling continuous operation with restricted airflow through the movable damper blade. This continuous operation avoids the mechanical, electrical, and thermal transients that occur during startup and shutdown, thereby preserving the operative lifetime of the HVAC unit while still achieving efficient electric power consumption.

Inventive Principle:

Principle #20Continuity of useful action

4Use of energy by moving object

If the HVAC unit operates with intermittent start-and-stop cycles, then the electric power consumption is reduced, but the startup and shutdown phases generate undesirable noise

Engineering Contradiction:

Improveelectric power consumptionVSAvoidnoise

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent eliminates the noisy startup and shutdown phases by enabling continuous operation with restricted airflow. The movable damper blade allows the HVAC unit to run continuously at reduced capacity, avoiding the intermittent cycling that generates undesirable noise during start and stop transitions, while maintaining efficient electric power consumption.

Inventive Principle:

Principle #20Continuity of useful action

5Use of energy by moving object

If the blower motor operates at less than optimal efficiency, then the electric power consumption is reduced, but waste heat generation increases

Engineering Contradiction:

Improveelectric power consumptionVSAvoidwaste heat

Core Design Contradiction:

Use of energy by moving objectVSLoss of energy

Solution Approach 1:

The patent introduces the movable damper blade as an intermediary device that restricts airflow through the HVAC unit. This intermediary mechanism allows the system to reduce electric power consumption by limiting airflow rather than reducing motor speed or power directly, thereby minimizing waste heat generation while achieving the desired reduction in energy consumption.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution effectively matches electric power consumption with actual heating or cooling loads, reducing noise and improving electrical efficiency by mechanically modulating airflow through the HVAC unit.

Implementation Method 1

an air control module connected between a high velocity blower and a distribution plenum selectively restricts volumetric airflow through the HVAC unit

Methodology Applied

Scientific EffectFluid flow restriction: Pressure Drop

Data Source

PatentUS9017156B2Air control module

Publication Date: 2015.04.28 MESTEK INC

AI summary

A damper blade is moved within an air control module connected to the discharge of a high-velocity blower, thereby modulating the electric power consumption of the blower motor.