ERV Cleat Mounting for Accurate Air Handler Installation
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Solution Overview
Problem
Existing energy recovery ventilators (ERVs) are cumbersome and costly to install with existing heating or cooling systems due to the need for multiple duct pipes and require complex wall controls, and their direct integration with furnace or air handler components is inaccurate and difficult.
Innovation Solution
The integration of interlocking mechanisms between the ERV and heating or cooling system components allows for direct and secure attachment, simplifying installation by aligning and locking the ERV into place using cleats that extend from the ERV and matching cleats on the system components, ensuring accurate positioning and sealing without damaging the gasket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ERV is mounted as a standalone heat exchanger remotely from the heating or cooling system, then the ERV can exchange heat or cool energy with the air handler system, but it requires four separate duct pipes and wall controls which makes installation costly and cumbersome
Solution Approach 1:
The patent combines the ERV unit with the air handler system by integrating it into the blower compartment, eliminating the need for separate duct pipes and wall controls. The ERV connects directly to the air streams within the air handler, merging two previously separate systems into one unified installation.
Solution Approach 2:
The ERV unit is designed to perform multiple functions: it recovers heat or cool energy from exhaust air, conditions fresh air, and integrates with the air handler's existing air distribution system. This multi-functionality eliminates the need for separate control systems and ductwork.
2Device complexity
If ERV is configured to connect directly to furnace or air handler blower compartment, then the need for four duct pipes is eliminated, but accurate positioning of ports and maintaining gasket integrity is difficult
Solution Approach 1:
The patent incorporates pre-positioned cleats on the air handler blower compartment that are designed to receive the ERV unit. These cleats are installed during air handler manufacturing, establishing precise mounting locations before the ERV is installed, thereby eliminating the need for complex field positioning.
Solution Approach 2:
The patent introduces cleats as an intermediary mounting mechanism between the air handler and the ERV. These cleats serve as a mediator that simplifies the connection process, allowing the ERV to be easily positioned and secured without requiring precise alignment of ports or complex gasket installation.
3Device complexity
If installation kit with chains or straps is used to hang the ERV from ceiling joist, then the ERV can be installed without four duct pipes, but the installation lacks accuracy and ease
Solution Approach 1:
The patent merges the mounting function into the air handler unit itself by incorporating cleats on the blower compartment. This eliminates the need for separate chains or straps and ceiling joist installation, as the air handler serves as both the functional component and the mounting structure.
Solution Approach 2:
The cleats on the air handler serve as an intermediary mounting mechanism that replaces complex chain and strap installations. These cleats provide a simple, accurate, and easy method for attaching the ERV directly to the air handler, eliminating the need for ceiling joist involvement.
Data Source
AI summary
An energy recovery system includes a heating or cooling system and an accessory operably connected to the heating or cooling system, or to a component of the heating or cooling system. One or more accessory interlocking mechanisms are located at the housing interlocked with one or more complementary interlocking mechanisms located at the system or the component of the heating or cooling system to secure the accessory directly to the component. A method of securing an accessory to a heating or cooling system or a component of a heating or cooling system includes aligning one or more accessory interlocking mechanisms with one or more interlocking mechanisms. The accessory is urged toward an installed position by moving the accessory along a length of the one or more complementary interlocking mechanisms. The one or more accessory interlocking mechanisms are interlocked with the complementary interlocking mechanisms to secure the accessory.