Field-Assembled HVAC Transition Panels for SEER-Preserving Airflow
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Solution Overview
Problem
HVAC systems face challenges when installing cased air conditioning evaporator coils on high SEER furnaces due to mismatched inlet and outlet dimensions, leading to reduced airflow and compromised SEER ratings, and existing transitions are bulky and costly to transport.
Innovation Solution
Field-assembled HVAC air conveyance apparatus using quadrilateral panels with right-angle flanges and hemmed cleats, allowing for secure assembly and transportation in a minimized footprint, with optional insulation and air purification coatings, and secure fastening with minimal tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If transitions are formed from sheet metal in an off-site shop and transported to a job site, then manufacturing precision is improved, but transportation costs and device complexity increase due to bulky shipping requirements
Solution Approach 1:
The transition is divided into multiple flat panels that can be stacked and transported in a compact configuration, then assembled on-site to form the complete transition structure. This segmentation allows precise manufacturing of individual panels while dramatically reducing transportation volume and complexity.
2Manufacturing precision
If transitions are formed as complete units in advance, then manufacturing precision is improved, but transportation costs increase due to bulky and structurally unsound shipping requirements
Solution Approach 1:
The complete transition assembly is segmented into multiple flat panels that can be stacked efficiently for transport. The panels are designed with integrated fastening features that allow precise reassembly on-site, maintaining manufacturing precision while dramatically reducing the weight and volume of the transported components.
3Manufacturing precision
If transitions are made as complete units, then manufacturing precision is improved, but transportation costs increase due to the need to mount on palettes
Solution Approach 1:
The transition is constructed from multiple flat panels that can be stacked and secured together without requiring external palettes or specialized shipping fixtures. The panels include integrated fastening features that enable easy stacking and handling during transport, greatly simplifying the manufacturing and shipping process while maintaining construction precision.
4Volume of moving object
If furnace outlet is smaller than coil inlet, then space utilization is improved, but airflow is reduced such that SEER ratings are not achieved
Solution Approach 1:
The transition panels are designed to create a three-dimensional tapered structure that smoothly transitions from the smaller furnace outlet to the larger coil inlet. This dimensional transition maintains optimal airflow velocity and volume throughout the connection, ensuring SEER ratings are achieved while adapting to the size difference between components.
Data Source
AI summary
The present heating, ventilation and air conditioning (HVAC) air conveyance apparatus is plurality of panels adapted to be field-assembled to form the conveyance apparatus. These panels include a pair of first quadrilateral panels, each defining a right-angle flange extending from each of a pair of opposite edges and a pair of second quadrilateral panels, each defining a hemmed cleat along each of a pair of opposite edges. Each hemmed cleat is shaped and dimensioned to receive one of the first quadrilateral panel right-angle flanges to form the HVAC air conveyance apparatus. Also, HVAC unit mating flanges extending from each other edge of each of the first quadrilateral panels and/or from each other edge of each of the second quadrilateral panels, such that at least a pair of opposed peripheral HVAC unit mating flanges extend from each end of the HVAC air conveyance apparatus.