Base system for air handler

Solution Overview

Problem

Manufacturing HVAC system housings with adequate structural rigidity is costly, time-intensive, and procedurally complicated, and existing designs suffer from thermal inefficiencies and limited rigidity.

Innovation Solution

A base system for HVAC systems featuring a frame with base rails and internal walls that provide increased structural rigidity and thermal breaks, including a geometry with a higher moment of inertia, allowing for reduced height and weight while improving assembly efficiency and thermal insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional housing designs with multiple structural components (base foundation, frame members, beams, wall panels, floor panels) are used, then the HVAC system provides adequate structural support, but the manufacturing process becomes complicated and time-intensive

Engineering Contradiction:

Improvestructural rigidityVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent combines multiple separate structural components (base foundation, frame members, beams, wall panels, floor panels) into a single integrated base rail structure. The base rail incorporates functions of the base foundation, frame members, and support structures into one unified component that provides all necessary structural support, thereby simplifying manufacturing while maintaining structural rigidity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The base rail is designed as a multi-functional component that simultaneously serves as the base foundation, structural frame, support beam, and mounting structure for HVAC equipment. This universal design eliminates the need for multiple specialized components, reducing manufacturing complexity and assembly steps while providing adequate structural support.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If traditional housing designs with multiple structural components are used, then the HVAC system provides adequate structural support, but the manufacturing cost increases

Engineering Contradiction:

Improvestructural rigidityVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent combines multiple separate structural components (base foundation, frame members, beams, wall panels, floor panels) into a single integrated base rail structure. The base rail incorporates functions of the base foundation, frame members, and support structures into one unified component that provides all necessary structural support, thereby simplifying manufacturing while maintaining structural rigidity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The base rail is designed with segmented geometry including base segments, external walls, top segments, internal walls, and recessed flanges that can be manufactured using standard forming processes. This segmentation allows the complex multi-functional structure to be produced efficiently through conventional manufacturing methods, reducing overall manufacturing cost.

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If existing housing designs are used, then the HVAC system can be assembled, but thermal inefficiencies occur

Engineering Contradiction:

Improveassembly efficiencyVSAvoidthermal efficiency

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The base rail incorporates thermal break features at specific locations where thermal bridges would otherwise occur between the HVAC equipment and the building structure. These localized thermal break provisions maintain assembly efficiency while preventing energy loss through the base structure.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11604008B2Base system for air handler

Publication Date: 2023.03.14 TYCO FIRE & SECURITY GMBH

AI summary

A base system for a heating, ventilation, and air conditioning (HVAC) system includes a frame configured to support a housing of the HVAC system, where the frame includes a base rail configured to define a portion of a perimeter of the frame. The base rail includes a base segment configured to be disposed on a curb in an installed configuration of the HVAC system, an external wall extending from the base segment, a top segment extending from the external wall, an internal wall extending from the top segment, and a recessed flange extending from the internal wall and away from the external wall.