Modular Air Handling Units for Commercial Applications

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001]This application claims priority to and benefit of U.S. provisional Ser. No. 63/636,178 filed Apr. 19, 2024, which is herein incorporated by reference.

FIELD

[0002]This disclosure relates generally to climate control systems. In particular, embodiments of the disclosure are related to modular air handling units that can be mixed and matched with other sub-systems of a climate control system.

BACKGROUND

[0003]Conventional climate control systems that are used to control climate in large premises, such like office buildings, schools, etc., include large air handling units that are often installed as a monolithic system. Once installed, they are often very hard to upgrade, such as to a higher capacity, if there is a need to do so. Accordingly, modular air handling units that are easier to transport, easier to install, easier to upgrade and provide the capability to be coupled with other individual sub-systems of a climate control system may be desired.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004]The detailed description is set forth with reference to the accompanying drawings. In some instances, the use of the same reference numerals may indicate similar or identical items. Various embodiments may utilize elements and/or components other than those illustrated in the drawings, and some elements and/or components may not be present in various embodiments. Throughout this disclosure, depending on the context, singular and plural terminology may be used interchangeably.

[0005]FIG. 1 illustrates a side view of an air handling unit according to an embodiment of the present disclosure.

[0006]FIG. 2 illustrates another side view of an air handling unit according to an embodiment of the present disclosure.

[0007]FIG. 3 illustrates a side view of a first portion of an air handling unit according to an embodiment of the present disclosure.

[0008]FIG. 4 illustrates another side view of the first portion of the air handling unit according to an embodiment of the present disclosure.

[0009]FIG. 5 illustrates a front view of the first portion of the air handling unit according to an embodiment of the present disclosure.

[0010]FIG. 6 illustrates a side view of a second portion of the air handling unit according to an embodiment of the present disclosure.

[0011]FIG. 7 illustrates another side view of the second portion of the air handling unit according to an embodiment of the present disclosure.

[0012]FIG. 8 illustrates a front view of the second portion of the air handling unit according to an embodiment of the present disclosure.

[0013]FIG. 9 illustrates a rear view of the second portion of the air handling unit according to an embodiment of the present disclosure.

[0014]FIG. 10 illustrates a bracket used for aligning the first and the second portions of the air handling unit according to an embodiment of the present disclosure.

[0015]FIG. 11 illustrates a functional block diagram of a modular air handling unit paired with two hot and cold energy supplying units according to an embodiment of the present disclosure.

[0016]FIG. 12 illustrates a functional block diagram of two air handling units connected in parallel according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

[0017]This disclosure relates generally to climate control systems that may be employed in commercial premises or residential units. More specifically, embodiments of the present disclosure relate to a modular air handling unit that can be easily transported, installed and paired with a variety of other sub-systems of a climate control system.

[0018]Convention air handling units, such as those installed in medium to big size buildings are often large in size and difficult to install and maintain. Once installed, a commercial air handling unit may be difficult to upgrade, and in some instances may not be upgraded until it reaches an end of useful life. In most instances, upgrading a commercial air handling unit involves replacing it with an entirely new system, which can be costly. While individual components within an air handling unit can be replaced, there is limited flexibility to upgrade an air handling unit due to the sheer size of the system, the need for special tools and equipment, and the potential unavailability of spare parts or components over time.

[0019]For situations where the capacity of an air handling unit needs to be upgraded due to increased demand of the specific premises being served by the air handling unit, such issues may be exacerbated. For example, consider a 10 ton capacity air handling unit is initially installed on a building. Over time, due to various factors, the demand for climate control load for that building increases and it becomes necessary to add capacity to the already installed air handling unit. If the new climate control requirements necessitate a 20 ton capacity air handling unit, there is no way currently to upgrade the existing 10 ton air handling unit in the field to the 20 ton capacity. Currently, the only option is to remove the old 10 ton air handling unit and install a brand new 20 ton air handling unit. This involves costs and disruption to the operation of that building. So, in most instances, the costs of system replacement outweigh the benefits, and the occupants of the building use the under-performing air handling unit.

[0020]Another issue with conventional air handling units is size, where unit size is large enough to require special space requirements to accommodate a footprint of the system, in both residential and commercial settings. So, in order to install an air handling unit in tight spaces, such as an attic of a house, basement of a building, etc., the entire air handling unit has to be dismantled, often to the individual component level, in order to transport the air handling unit to such tight spaces. Then the air handling unit has to be re-assembled at the final location. Such tasks result in increased labor and material costs, and can also require shipment of air handling units in dis-assembled form, transport of individual components to a final installation location, and re-assembly of the air handling unit at the final location.

[0021]Embodiments of the present disclosure solve the above issues by having a modular air handling unit that can be transported easily, fits through most conventional access paths, such as doorways, attic openings, etc., can be installed easily and quickly, and can be paired with other components of a climate control system, such as furnaces, to provide versatility in terms of the amount of load that the air handling unit can support, and is upgradable in the field. This results in reduced cost both to the manufacturer and users, and provides users the ability to continually adapt the air handling unit to meet new operational demands or new regulatory mandates that the industry may adopt.

[0022]FIG. 1 is a side view of an air handling unit 100 according to an embodiment of the present disclosure. Air handling unit 100 includes a first separable portion, which may be an air intake portion 102, and a second separable portion, which may be an air outlet portion 104. The first and the second separable portions may be separated from each other. The details of each of the first and the second separable halves are described below with reference to other figures. Air handling unit 100 includes a filter unit 106. Filter unit 106 may include a single filter or multiple filters stacked together. In some embodiments, the multiple filters of the filter unit 106 may include the same type of filters. In another embodiment, the multiple filters of the filter unit 106 may include different types of filters that filter out particulate matter of different sizes. These filters may be realized using any known filters in the art. The main function of the filter unit 106 is to trap particles flowing through the filter unit 106, so as to prevent movement of particles from the ingested air to the other components of air handling unit 100. This helps to not only keep the internal components of air handling unit 100 clean and operational, but also ensures that the air being supplied to the associated premises is filtered of particles.

[0023]Air handling unit 100 further includes a cooling coil assembly 108. Cooling coil assembly 108 may be coupled to a cooling source (not shown) such as a chiller or a refrigeration unit. The cooling source provides a cooling fluid, such as water, refrigerant, air, etc., that circulates through cooling coil assembly 108. When another fluid, such as air, passes over the cooling coil assembly 108 it loses some of its heat and cools down. Thus, cooling coil assembly 108 acts like a heat exchanger which transfers the heat from the air to the cooling fluid and transfers the cold from the cooling fluid to the air. This results in the air cooling down as it passes over the cooling coil assembly 108. Cooling coils assembly 108 has an inlet port and an outlet port that allow the cooling fluid to circulate through the cooling coil assembly 108. Cooling coil assembly 108 also includes one or more fins to facilitate heat exchange between the cooling fluid and the air passing over the cooling coil assembly 108. In some embodiments, the cooling coil assembly 108 may serve the dual functions of being a condenser or an evaporator based on the mode of operation of the air handling unit 100.

[0024]Air handling unit 100 may also include a heating coil assembly 110. Heating coil assembly 110 is coupled to a heating source (not shown). The heating source may be any suitable heating source, such as a furnace, a heat pump, or a boiler. The heating source provides a heated fluid, such as a refrigerant, air, water, etc., that circulates through the heating coil assembly 110. Heating coil assembly 110 acts as another heat exchanger unit that heats or warms the air as it passes over the heating coil assembly 110. As the air passes over heating coil assembly 110, it absorbs the heat from the heated fluid circulating with the heating coil assembly 110 and rises in temperature and may also lose some of its humidity. In some embodiments, the heating coil assembly 110 may be used to remove moisture from the outside air ingested by the air handling unit 100 and cooled using the cooling assembly 108. The heating coil assembly 110 may be optional and not always present in the air handling unit 100.

[0025]Air handling unit 100 also includes an air inlet port 117. The air inlet port 117 serves to ingest air from outside into air handling unit 100. The air may be supplied to the air handling unit 100 through one or more return air ducts for recirculating air within a building and/or one or more economizers, energy recovery ventilator (ERV), or other such component for receiving the outdoor air. Air ingested via the air inlet port 117 passes through the filter unit 106 before being heated or cooled by the respective cooling coil assembly 108 or heating coil assembly 110. Air inlet port 117 can be realized using any known technique in the art. In the example shown in FIG. 1, the air inlet port 117 is located on a sidewall of the air intake portion 102 and is horizontally aligned with the cooling coil assembly 108 and the air outlet portion 104. In some implementations, the air inlet port 117 may be positioned above the cooling coil assembly 108.

[0026]Air intake portion 102 can include additional components that are not shown, such as pressure sensors, leak sensors, etc. One skilled in the art will realize that an air handling unit includes other components, however, the explanation of these components is omitted here for brevity. However, all such conventional components can be included in air intake portion 102.

[0027]The air outlet portion 104 of the air handling unit 100 further includes a blower unit 111. The blower unit 111 includes a motor 112, a housing 114, an inlet port (not shown), and an outlet port 116. Motor 112 turns a fan or impeller (not shown) located within the housing 114 of the blower unit 111. While the motor 112 is shown as being affixed to the housing 114, in some implementations, the motor 112 may be affixed to other structures within the air outlet portion 104. Housing 114 may include other components (not shown). The outlet port 116 is coupled to ductwork (not shown) for distributing conditioned air throughout a building. One skilled in the art will realize that air outlet portion 104 may include other components, the description of which is omitted here for brevity. Such components may be derived from conventional air handling units. All or many of such components may also be included in air handling unit 100.

[0028]In operation, motor 112 operates to draw air into the air intake portion 102 by creating a pressure differential and/or suction. The air passes through the filter unit 106 where it is cleaned and contaminants are removed from the air. The air is then either heated or cooled, depending on the desired temperature within the premises, using the cooling coil assembly 108 or heating coil assembly 110, which act as two heat exchangers. The cleaned cooled or heated air is drawn into housing 114 of the blower unit and is output via air outlet port 116. The air then passes through the associated ductwork to the desired section or portion of the premises. Air handling unit 100 as described above is the part of the air intake and conditioning portion of the overall climate control system. It is to be noted that the flow of air within the air handling unit 100 occurs in a horizontal path or direction. Specifically, air is ingested via the air inlet port 117 of the first portion 102. The air then passes over the cooling coil assembly 108 and via the filter unit 106. The air leaves the first portion 102 and enters the second portion 104. The air in then drawn by the blower unit 111 and directed towards the air outlet port 116. The components within the air handling unit 100 are arranged such that the air follows a horizontal path as it flows from the air intake port 117 to the air outlet port 116. A second air handling unit, similar to the air handling unit 100, with same or less components may be installed to gather air from within the premises and expel that air to the outside of the building. The second air handling unit works in a reverse manner in which the air from within the premises enters the air handling unit and the air is then expelled to the outside of the premises. However, for the purposes of this disclosure, the air handling unit 100 is described as it is used in the air intake and conditioning process. One skilled in the art will realize that a similar air handling unit 100 can be used in the air output process.

[0029]FIG. 2 illustrates another side view of air handling unit 100 according to an embodiment of the present disclosure. The side view of FIG. 2 is from an opposing side relative to the view shown in FIG. 1. As shown in FIG. 2, air handling unit 100 is constructed such that air intake portion 102 and the air outlet portion 104 can be joined together to from air handling unit 100. Each separable portion can be built and shipped separately for final assembly in the field.

[0030]FIG. 3 is a detailed view of the air intake portion 102 according to an embodiment of the present disclosure. As described above, air intake portion 102 is the air intake portion of air handling unit 100. In an embodiment, air intake portion 102 may be a quadrilateral in shape in order to provide it with the mechanical rigidity. Air intake portion 102 may include a common frame member 120. The common frame member 120 may be shared with the air outlet portion 104, as shown in FIG. 1. In an embodiment, the common frame member 120 may span the entirety of air intake portion 102 and air outlet portion 104 and provide additional mechanical strength to both portions once the two portions are joined together. Common frame member 120 may be constructed of any suitable metal or other rigid material that can accomplish the intended function. In some embodiments, the common frame member 120 is optional and not required.

[0031]In order to make air intake portion 102 a fully separable portion of air handling unit 100, so that it can be shipped separately as well as have the mechanical strength to maintain its shape once the entire air handling unit is assembled, air intake portion 102 has its own frame structure. This frame structure is primarily defined by four structural members, including a first structural member 122, a second structural member 124, a third structural member 126, and a fourth structural member 128. First structural member 122 may be located just beneath and parallel to common frame member 120. First structural member 122 may be coupled to common frame member 120 at one or more points along the length of common frame member 120. In one embodiment, the length of first structural member 122 may be about half of the length of common frame member 120. Second structural member 124 is coupled to first structural member 122 such that first structural member 122 is orthogonal to second structural member 124. In one embodiment, first structural member 122 may form a right angle with second structural member 124. Second structural member 124 may be connected to an air intake port 132, via which the outside air is ingested into air intake portion 102. Second structural member 124 may be constructed using any known metal or other rigid material that satisfies the mechanical requirements specified by the manufacturer.

[0032]Second structural member 124 is coupled to a base member 126. Base member 126 is located towards the bottom of air intake portion 102 once the air handling unit 100 is installed at the site. Base member 126 is coupled to structural member 124 at one more points using bolts or other similar fasteners. In one embodiment, base member 126 is positioned orthogonal to second structural member 124 and parallel to first structural member 122. In an embodiment, base member 126 may be substantially equal in length to first structural member 122. In this context, substantially means with +/−10% of the length of first structural member 122. Base member 126 may be realized using any known metal or rigid material in the art.

[0033]In an embodiment, the filter unit 106, cooling coil assembly 108, and the heating coil assembly 110 may each be coupled to one or more of the second structural member 124 and the base member 126 at a bottom portion of air intake portion 102. In one embodiment, the filter unit 106 may be coupled either to second structural member 124, or base member 126 or to both at the bottom portion of air intake portion 102. Filter unit 106 is positioned in an inclined orientation such that an axis ‘A’ running along the length of the filter unit 106 and axis ‘B’ running along the length of base member 126 form an angle. In one embodiment, the angle is between 35 and 55 degrees. In a particular embodiment, the angle is 45 degrees. Similarly, cooling coil assembly 108 is positioned in an inclined orientation with respect to base member 126. Axis ‘C’ that runs along a length of cooling coil assembly 108 makes an angle with axis ‘B’. In one embodiment, the angle between axes ‘B’ and ‘C’ may be between 35 and 55 degrees. In a particular embodiment, this angle is about 45 degrees. Further, the heating coil assembly 110 may also be positioned in an inclined orientation with respect to base member 126. An axis ‘D’ running along the length of the heating coil assembly 110 may define an angle with respect to axis ‘B’. In some embodiments, the angle formed by axes ‘D’ and ‘B’ may be between 35 and 55 degrees. In a particular embodiment, the angle is about 45 degrees. In some embodiments, filter unit 106, cooling coil assembly 108, and heating coil assembly 110 may all be oriented parallel to each other. In an embodiment, filter unit 106 may be directly in contact with cooling coil assembly 108, and the cooling coil assembly 108 may be directly in contact with heating coil assembly 110. In other embodiments, there may be separation between one or more of: the filter unit 106, cooling coil assembly 108, and heating coil assembly 110, if present.

[0034]Air intake portion 102 may include the fourth structural member 128 that is coupled to base member 126 and first structural member 122. Fourth structural member 128 is orthogonal to both base member 126 and first structural member 122. In an embodiment, filter unit 106, cooling coil assembly 108, and heating coil assembly 110 may be individually connected to fourth structural member 128 and first structural member 122 at a top portion of air intake portion 102. Similar to above, an axis ‘E’ running along a length of structural member 122 may form an angle with each of the axis ‘A’, ‘C’, and ‘D.’ In one embodiment, each of these angles may be between 35 degrees and 55 degrees. In a particular embodiment, all these angles may be about 45 degrees. As seen in FIG. 3, the first structural member 122, second structural member 124, third structural member 126, and fourth structural member 128 form a quadrilateral structure that provides structural integrity to air intake portion 102. In an embodiment, first structural member 122 is located towards a top end of air intake portion 102 and is parallel to third structural member 126. The third structural member 126 may be located at the bottom end of air intake portion 102. Second structural member 124 is located towards back portion of air intake portion 102 and is parallel to fourth structural member 128 that is located towards a front end of air intake portion 102. Fourth structural member 128 is coupled to a connection surface 130 or has a connection surface 130. Connection surface 130 includes one or more features that enable air intake portion 102 to be coupled to the air outlet portion 104, as discussed below.

[0035]While air intake portion 102 as shown in FIG. 3 is substantially square in shape, it is to be understood that any other quadrilateral shape will work as long as the proper structural integrity is provided. In other embodiments, shapes other than a quadrilateral shape are also possible. For example, air intake portion 102 may have a polygonal shape, a cylindrical shape, or any other shape that provides the structural strength and stability.

[0036]FIG. 4 illustrates another side view of air intake portion 102 according to an embodiment of the present disclosure. The view shown in FIG. 4 is from an opposing side relative to the view shown in FIG. 3. As shown in FIG. 4, air intake portion 102 includes also includes several structural members, such as a fifth structural member 122a, a sixth structural member 124a, a seventh structural member 126a, and an eighth structural member 128a that are oriented in a similar manner as the respective corresponding structural members (e.g., first structural member 122, second structural member 124, third structural member 126, and fourth structural member 128). All these structural members together, and with other structural members not shown, form the overall housing of air intake portion 102 in which all of the other components of air intake portion 102 are housed. Fifth structural member 122a, the sixth structural member 124a, the seventh structural member 126a, and the eighth structural member 128a are of similar construction as the first structural member 122, the second structural member 124, the third structural member 126, and the fourth structural member 128, respectively, described above. Filter unit 106, cooling coil assembly 108, and heating coil assembly 110 form similar angles as described above with the sixth structural member 122a and seventh structural member 126a.

[0037]FIG. 5 illustrates a front view of air intake portion 102 according to an embodiment of the present disclosure. FIG. 5 illustrates details of the connection surface 130 mentioned above. Connection surface 130 mates with a corresponding connection surface of the air outlet port 104, as described in detail below. Connection surface 130 may include one or more faceplate members, including a first faceplate member 132, a second faceplate member 134, a third faceplate member 136, and a fourth faceplate member 138. Each of these face plate members may be planar having a certain thickness. In an embodiment, each of the face plate members may be coupled to one or more of structural members. In an embodiment, the first faceplate member 132, the second faceplate member 134, the third faceplate member 136, and the fourth faceplate member 138 may be arranged in a quadrilateral pattern similar to the first structural member 122, the second structural member 124, the third structural member 126, and the fourth structural member 128 and the fifth structural member 122a, the sixth structural member 124a, the seventh structural member 126a, and the eighth structural member 128a described above.

[0038]In one embodiment, the first faceplate member 132 may include one or more connection features 140. Connection features 140 may be simple openings through which bolts or other similar fasteners may be introduced and connected to the corresponding connection surface of air outlet portion 104. One skilled in the art will realize that any other suitable fastener may be used to connect air intake portion 102 with air outlet portion 104. Since both the air intake portion 102 and air outlet portion 104 may be heavy and/or may be installed in tight spaces, it is advantageous to have some sort of mechanism that facilitates easy alignment of the two portions. Proper alignment of the two portions allows for proper operation of air handling unit 100. In order to enable easier alignment of the air intake portion 102 and air outlet portion 104, one or more alignment features 142 may be provided at or more corners of the connection surface 130. Alignment features 142 may include a guide or dowel and pin and hole, tongue and groove, slot and protruded member, etc. In one embodiment, a tool-less connection technique may be used to align and connect the air intake portion 102 and air outlet portion 104. One skilled in the art will realize that any other alignment feature that serves the purpose may also be used.

[0039]FIG. 6 illustrates a close-up side view of air outlet portion 104 of air handling unit 100 according to an embodiment of the present disclosure. As mentioned above, air outlet portion 104 is a separable and self-contained unit that can be manufactured and shipped separately as a single unit. Similar to air intake portion 102, the air outlet portion 104 also includes several structural members that provide the mechanical rigidity and stability to the air outlet portion 104. Specifically, air outlet portion 104 may include a first structural member 202 that is oriented horizontally and it located at a top end of portion 104. In some embodiments, first structural member 202 is in contact with the common frame member 120 that spans the entire length of air handling unit 100. First structural member 202 is disposed below and is parallel to common frame member 120.

[0040]Air outlet portion 104 further includes a second structural member 204. Second structural member 204 is connected to first structural member 202 and is orthogonal to first structural member 202. In some embodiments, second structural member 204 forms a right angle with first structural member 202. In an embodiment, second structural member 204 may include a slot opening 232. Slot opening 232 along with a corresponding alignment bracket (not shown) is used to easily and properly align the air outlet portion 104 with a corresponding air intake portion 102. Details of the bracket and alignment process is described below in relation to FIG. 10. In other embodiments, slot opening 232 may be located on structural member 128 of air intake portion 102. Second structural member 204 may also include one or more connection features 234 that may be used in conjunction with slot opening 232 and associated bracket to connect and secure the air intake portion 102 and the air outlet portion 104. Connection features 234 may be openings for use with fasteners such as bolts, screws, etc. In other embodiments, connection features may be specialized features such as tool-less locking mechanism, dowel pins, etc.

[0041]Air outlet portion 104 may further include a base structural member 206. Base structural member 206 is connected to second structural member 204 and is orthogonal to member 204. In an embodiment, base structural member 206 and second structural member 204 form a right angle. Base structural member 206 is located towards a bottom end of air outlet portion 104. Air outlet portion 104 may include a third structural member 208 that is connected to the first structural member 202 and the base member 206, and is orthogonal to both the first structural member 202 and the base member 206. Each of the structural members are a portion of the overall housing of air outlet portion 104 and define an interior space in which the components of air outlet portion 104 are housed. Second structural member 204 also defines a portion of connection surface 230. This connection surface 230 mates with the corresponding connection surface 130 of air intake portion 102 in order to complete the air handling unit 100. Details of connection surface 230 are provided below. Third structural member 208 is coupled to an air outlet port 210. Air drawn by motor 112 and blower unit 111 is expelled via the air outlet port 210. This air outlet port 210 is coupled to one or more ducts that direct the air to the appropriate location within the premises. The structural members may be constructed similarly to the structural members described above. First structural member 202 may have a length that is about half of the length of common frame member 120. In one embodiment, each of the structural members may be of equal length. In another embodiment, each of the structural members may all be of equal thickness and/or width.

[0042]FIG. 7 illustrates another side view of air outlet portion 104 according to an embodiment of the present disclosure. The view illustrated in FIG. 7 is from a side that is opposite to the side illustrated in FIG. 6. As seen from this side view, air outlet portion 104 includes at least four more structural members, such as a first structural member 202a, a second structural member 204a, a third structural member 206a, and a fourth structural member 208a. These structural members are placed and oriented similarly to their corresponding structural members (e.g., first structural member 202, second structural member 204, third structural member 206, and fourth structural member 208) respectively. These eight structural members, along with one or more additional structural members together define a housing for air outlet portion 104 and provide the structural rigidity and stability. Just like air intake portion 102 above, air outlet portion 104 can also be built and shipped individually to the installation location. Since the air intake portion 102 and the air outlet portion 104 are fairly compact, they can be carried through most standard openings in buildings and residential areas. In an embodiment, the dimension of each of the air intake portion 102 and the air outlet portion 104 may be 52 inch height×52 inch width, enabling easy transportation and carrying. In other embodiments, air intake portion 102 and the air outlet portion 104 may have dimensions that allow them to be carried through standard residential door openings, such as 36 inches.

[0043]In an embodiment, second structural member 204a may include another slot opening 232a. Slot opening 232a may be similar to slot opening 232 described above and help with aligning the air intake portion 102 and the air outlet portion 104. In some embodiments, structural member 204a may include one or more connection features 234a. Connection feature 234a can be similar to connection feature 234 described above.

[0044]FIG. 8 illustrates a view of air outlet portion 104 looking via the connection surface 230 according to an embodiment of the present disclosure. This view can also be referred to as the front view of air outlet portion 104. Connection surface 230 may include one or more planar members, including a first planar member 240, a second planar member 242, a third planar member 244, and a fourth planar member 246. Each of these planar members may have one or more connection features 248. In some embodiments, connection feature 248 may simply be an opening that is configured to accept a fastener such as a bolt, a screw, or similar. In other embodiments, connection features 248 may be more specialized like tool-less connection mechanisms that are known in the art. Connection features 248 align with corresponding connection features 140 on connection surface 130 of air intake portion 102 provide a robust connection interface for aligning and joining the air intake portion 102 and air outlet portion 104. In some embodiments, one or more additional connection features 250 may also be present that may help with aligning the air intake portion 102 and air outlet portion 104 or provide additional fastening means. As noted above, during installation, connection surface 230 mates with connection surface 130 of air intake portion 102.

[0045]FIG. 9 illustrates a different view of air outlet portion 104 according to an embodiment of the present disclosure. The view shown in FIG. 9 may be referred to as back view of air outlet portion 104. In this view, it can be seen that air outlet port 210 is coupled to two vertical members, including a first vertical member 260a and a second vertical member 260b. The first vertical member 260a and second vertical member 260b span most (e.g., more than half, etc.) of the height of air outlet portion 104. In addition to providing connection points for air outlet port 210, the first vertical member 260a and second vertical member 260b also provide additional structural support to air outlet portion 104. This helps maintain the structural rigidity of air outlet portion 104 since the blower unit 111 and motor 112 are heavy. Without this additional structural support, it may be difficult for the air outlet portion 104 to maintain its structural integrity during transportation and after installation. In an embodiment, both first vertical member 260a and second vertical member 260b can be of equal height and thickness. In other embodiments, they may be of a different height or thickness. Also, the materials that constitute first vertical member 260a and second vertical member 260b can be the same or different. One skilled in the art will realize various ways of realizing first vertical member 260a and second vertical member 260b.

[0046]FIG. 10 illustrates an alignment bracket 300 according to an embodiment of the present disclosure. As noted above, alignment bracket 300 works in conjunction with slot opening 232 and one or more connection features 312 present on structural member 128 of air intake portion 102, as illustrated in FIG. 3. Alignment bracket 300 includes a first planar portion 302 and a second planar portion 304. Second planar portion is connected flexibly to first planar portion 302 via a flexible portion 308. First planar portion 302 includes connection features 306. In an embodiment, connection features 306 align with connection features 312 after bracket 300 is placed in position. Once in position, a fastener can be inserted into connection features 306 and 312. The second planar portion 304 has a thickness that enables it to be inserted into the slot opening 232 of the air outlet portion 104. During installation, the air intake portion 102 and the air outlet portion 104 are first brought close together and aligned using one or more of the alignment features described above. Once the air intake portion 102 and the air outlet portion 104 are close enough, second planar portion 304 of bracket 300 is inserted into slot 232 and the first planar portion 302 is placed over a portion of the fourth structural member 128. The connection features 306 and 312 then self-align with each other. One or more fasteners are then inserted through the connection features 306 and 312. Once those fasteners are tightened, both the air intake portion 102 and air outlet portion 104 mate with each other with the correct alignment. Use of bracket 300 greatly simplifies the alignment and installation of air handling unit 100. Bracket 300 can be realized using any appropriate material known in the art. Flexible portion 308 may be similar to a hinge mechanism and may be realized using any known suitable material in the art.

[0047]The modular air handling unit 100 greatly simplifies the installation process and provides enhanced flexibility for system upgrades in the field. Since the air intake portion 102 and air outlet portion 104 are completely separable, it is easier to handle each of these individual portions and that increases the field reparability and upgrade for air handling unit 100. In some instances, air intake portion 102 may also be referred to as the “coil portion” since the air intake portion 102 mainly includes the cooling coil assembly 108, the heating coil assembly 110, and the filters. Air outlet portion 104 may be referred to as “fan portion” since it mainly includes the blower unit. Thus, each of the coil portion and the fan portion are individually replaceable and repairable. In addition, each of air intake portion 102 and the air outlet portion 104 can be individually coupled to other sub-systems of the overall climate control system, providing additional functionality that was not possible previously. FIGS. 11 and 12 illustrate two embodiments in which the individual air intake portion 102 and the air outlet portion 104 of air handling unit 100 are configured in a manner that was not possible without the above-mentioned modular approach.

[0048]FIG. 11 illustrates a block diagram of a system 450 according to an embodiment of the present disclosure. System 450 demonstrates one of the advantages of having a modular air handling unit. System 450 includes an air intake portion 400 of an air handling unit. In an embodiment, air intake portion 400 may be similar to the air intake portion 102 described above. Air intake portion 400 includes a heat exchanger 402. In an embodiment, heat exchanger 402 may be a heating coil and similar to the heating coil assembly 110 or cooling coil assembly 108 described above. Air intake portion 400 also includes an air inlet port 414. The air inlet port 414 serves to ingest air from outside the premises and may be similar to the air inlet port 117 described above. Air that is ingested via port 414 passes over the heat exchanger 402 before being expelled out of system 450.

[0049]It is to be noted that air intake portion 400 includes many more components than shown in FIG. 11 as is evident from the description of air intake portion 102 above. However, for ease of explanation, the other components of air intake portion 400 are not shown here. For example, air intake portion may have multiple heat exchangers and one or more filter units, as described above in relation to air handling unit 100. The air intake portion 400 of the air handling unit can be paired with one more heating or cooling units, more generically referred herein as energy supplying units. In FIG. 11, a first energy supply unit 420 and a second energy supply unit 422 are shown, but one skilled in the art will realize that the air intake portion 400 can be coupled to one or more energy supply units and it not limited to two energy supply units as shown in the figure. In an embodiment, the first energy supply unit 420 and the second energy supply unit 422 can be similar to the residential furnaces that are known in the art. In another embodiment, the first energy supply unit 420 and the second energy supply unit 422 can be boilers or heat pumps that can supply a heated fluid to heat exchanger 402. In yet another embodiment, the first energy supply unit 420 and the second energy supply unit 422 can be chillers or heat pumps that can supply a cold fluid to heat exchanger 402. In practice, the first energy supply unit 420 and the second energy supply unit 422 can be simpler since they don't need to include any filters or heat exchangers because those functions are performed by the air intake portion 400. As shown, the first energy supply unit 420 includes a first blower unit 404 and a first heating or cooling (e.g., energy) source 410. The first heating or cooling source 410 can be a gas furnace, a fluid boiler, chiller, or a heat pump that provides a heated or cooled refrigerant. Similarly, the second energy supply unit 422 includes a second heating or cooling source 412 and a second blower unit 408.

[0050]In order to realize system 450 in the field, the air intake portion 400, the first energy supply unit 420 and the second energy supply unit 422 are shipped separately as individual units. During installation, the technician can couple the first energy supply unit 420 and the second energy supply unit 422 to the air intake portion 400 using some of the alignment and connection techniques described above. In an embodiment, a custom interface adapter can be used to couple air intake portion 400 with the first energy supply unit supply unit 420 or the second energy supply unit 422. Once the air intake portion 400, the first energy supply unit 422, and the second energy supply unit 420 are physically connected, the various other plumbing and electrical connections between them can be performed in order to finish the installation. As can be seen from above, having these modular units is more efficient and costs less than installing a traditional air handling unit. Also, since these units are physically smaller and lighter than their conventional counterparts, it is easy for technicians to carry and install them in the field. Also, these units are very easy to upgrade and repair in the field. For example, consider that initially, system 450 is set up with a capacity of 10 tons. A few years after, the requirements for the premises change and now there is a need for the climate control system to have a capacity of 20 tons. In a conventional system, the entire air handling unit would need to be removed and replaced with a higher capacity system. However, with the modular approach shown in FIG. 11, it is possible to only replace the air intake portion 400 with a higher capacity unit without the need to change the first energy supply unit 420 or the second energy supply unit 422 or vice versa. This saves both time and money for the customer while meeting the ever changing needs for climate control.

[0051]In operation, air from outside the premises is ingested by air intake portion 400 by operation of blower unit(s) 404 and 408. The first energy supply unit 420 and the second energy supply unit 422 provide a hot or cold fluid to heat exchanger 402, depending on the temperature set point for the premises and the mode of operation of system 450 (e.g., cooling mode or heating mode). For example, in a heating mode of operation, as the air passes over heat exchanger 402 it absorbs the heat from the hot fluid circulating in the heat exchanger 402 and increases in temperature. The heated air then passes via the first energy supply unit 422 or the second energy supply unit 420 and is then expelled out of the into the corresponding ductwork to be distributed to the desired areas of the premises.

[0052]In a cooling operation, the air ingested from outside the premises passes over heat exchanger 402. The first energy supply unit 420 and/or the second energy supply unit 422 provide a cold fluid that circulates within heat exchanger 402. As the outside air passes over heat exchanger 402, it will transfer its heat to the cool fluid circulating in heat exchanger 402. As a result, the temperature of the air will drop. This cooled air will then be directed by the first blower unit 404 or the second blower unit 408 towards the corresponding duct work to be provided to the desired areas of the premises.

[0053]In another embodiment, one of the first energy supply unit 420 or the second energy supply unit 422 can be a heating unit and the other can be a cooling unit. In this instance, air intake portion 400 will have two heat exchangers, each coupled to one of the first energy supply unit 420 or the second energy supply unit 422. The operation of such a system would be similar to what is described above.

[0054]Another advantage of system 450 is that each of the air intake portion 400, the first energy supply unit 420, and the second energy supply unit 422 can be individually controlled to provide the right amount of cold or hot air to the premises. For example, consider that the first energy supply unit 420 serves a first portion of the premises and the second energy supply unit 422 serves a second portion of the premises. Depending on the temperature for each of these portions, the appropriate amount of air can be directed to each of these portions. However, since the heat exchanger portion, i.e. air intake portion 400, is common between both the first energy supply unit 420 and the second energy supply unit 422, only the amount of air travelling through each of these energy units needs to be controlled in order to achieve the desired results. This simplifies the control logic for system 450. It is to be noted that air flow through the system 450 is in a horizontal path. Air is ingested via the air inlet port 414. This air after it passes over the heat exchanger 402 is directed along a horizontal or transverse path towards the first blower unit 404 and the second blower unit 408. The air is further directed along the horizontal path from the first blower unit 404 to the first heating or cooling source 410 and from the second blower 408 towards the second heating or cooling source 412. The air then leaves the first energy supply unit 420 and the second energy supply unit 422 along the horizontal path, as shown in FIG. 11.

[0055]Further, depending on the climate control needs, the amount of hot or cold fluid provided to the heat exchanger 402 by each of the first energy supply unit 420 and the second energy supply unit 422 via common plumping lines 416 can be controlled individually. For instance, during times of reduced heating or cooling loads, one of the first energy supply unit 420 or the second energy supply unit 422 can be turned off or run at a reduced capacity thus lowering the operating costs for the customer. In another instance, when one of the first energy supply unit 420 or the second energy supply unit 422 needs maintenance or repair, the other unit can still keep running, providing some level of climate control in the premises. Without such a modular approach, any repair or maintenance event of an air handling unit currently results in the entire system being offline, often for long periods of time. Obviously, this is not desirable and is an inconvenience to the customer. With the modular approach illustrated in FIG. 11, system 450 can continue to work, may be in a reduced capacity, while the repair or maintenance work is being performed. The same is true in the case when one of the first energy supply unit 420 or the second energy supply unit 422 has to be replaced for any reason. Even in that instance, system 450 can continue to run while the affected unit is being replaced.

[0056]FIG. 12 illustrates a block diagram of a twinned air handling unit set up 500 according to an embodiment of the present disclosure. In this embodiment, two modular air handling units, a first modular air handling unit 502 and a second modular air handling unit 504 are connected in parallel. Each of the first modular air handling unit 502 and second modular air handling unit 504 is similar to air handling unit 100 described above. The first modular air handling unit 502 includes a first air intake portion 506 and a first air outlet portion 510. In an embodiment, the first air intake unit 502 is similar to air intake portion 102 and the first air outlet portion 510 is similar to air outlet portion 104 described above. The second modular air handling unit 504 includes a second air intake portion 508 and a second air outlet unit 512. In an embodiment, the second air intake portion 508 is similar to air intake portion 102 and the second air outlet portion 512 is similar to air outlet portion 104 described above.

[0057]The first air intake portion 506 includes a first heat exchanger 518 and a second heat exchanger 520. The second air intake portion 508 includes a third heat exchanger 522 and a fourth heat exchanger 524. The first heat exchanger 518 and the second heat exchanger 522 may be similar to cooling coil assembly 108 described above and third heat exchanger 520 and the fourth heat exchanger 524 may be similar to the heating coil assembly 110 described above. Each of the first heat exchanger 518 and the second heat exchanger 522 may be connected to a heat source 514. Heat source 514 may be a furnace, a boiler, or a heat pump that provides a hot or heated fluid to the first heat exchanger 518 and the second heat exchanger 522. Each of the third heat exchanger 520 and the fourth heat exchanger 524 may be connected to a cooling source 516. Cooling source 516 may be a chiller or a heat pump that provides a cool or cold fluid to the third heat exchanger 520 and the fourth heat exchanger 524. Each of the heat source 514 and cooling source 516 are individually controlled to regulate the amount of hot or cold fluid provided individually to each of the four heat exchangers.

[0058]The first modular air handling unit 502 also includes a first air outlet portion 510 and the second modular air handling unit 504 includes a second air outlet portion 512. Each of the first air outlet portion 510 and the second air outlet portion 512 are connected to associated duct work (not shown). In an embodiment, the first air outlet portion 510 and the second air outlet portion 512 are similar to air outlet portion 104 described above. Operation of the first modular air handling unit 502 and the second modular air handling unit 504 is similar to operation of air handling unit 100 described above and is not repeated here.

[0059]There are several advantages to the twinned combination illustrated in FIG. 12. Each of the first air intake portion 506, the first air outlet portion 510, the second air outlet portion 512, and the second air intake portion 508 is modular and individually replaceable and serviceable. Therefore, in the event that any one of these units has to be repaired or replaced, the entire system 500 need not be idle. A portion of system 500 is still operational while the affected portion of system 500 is being serviced or replaced. Further since each of the heat source 514 and cooling source 516 can be individually controlled, the amount of heated or cooled fluid provided to each of the first modular air handling unit 502 and the second modular air handling unit 504 can be controlled based on the heating or cooling requirements of the premises. Further, depending on the heating or cooling load, one of the first modular air handling units 50 or the second modular air handling unit 504 can be turned off or run at reduced capacity, thereby saving energy and reducing wear and tear on the air handling units. For example, for an office building, the heating or cooling load during nighttime is much less and hence one or both of the first modular air handling units 502 and the second modular air handling unit 504 may be run at reduced capacity or one of them could be completely turned off.

[0060]In other instances, if one or more of the heat exchangers needs to be replaced, the remaining heat exchangers can still function normally and the system 500 can still keep operating. Even though FIG. 12 shows a twinned air handling unit system, it is to be noted that more than two air handling units can also be connected in a similar fashion and there is no restriction on the number of air handling units that can be connected. Further, the placement of air handling units when connected in this manner can be varied too. For example, two or more air handling units may be vertically stacked on top of each other, placed adjacent to each other with each air handling unit being connected to the floor or ground or in any other suitable configuration. Since the individual portions of the air handling units are smaller and lighter, it opens up the possibility of various ways of arranging them depending on the available space, capacity needs, and local regulations.

[0061]Ranges may be expressed herein as from “about” or “approximately” or “substantially” one particular value and/or to “about” or “approximately” or substantially” another particular value. When such a range is expressed, the disclosed technology can include from the one particular value and/or to the other particular value. Further, ranges described as being between a first value and a second value are inclusive of the first and second values. Likewise, ranges described as being from a first value and to a second value are inclusive of the first and second values.

[0062]Herein, the use of terms such as “having,” “has,” “including,” or “includes” are open-ended and are intended to have the same meaning as terms such as “comprising” or “comprises” and not preclude the presence of other structure, material, or acts. Similarly, though the use of terms such as “can” or “may” are intended to be open-ended and to reflect that structure, material, or acts are not necessary, the failure to use such terms is not intended to reflect that structure, material, or acts are essential. To the extent that structure, material, or acts are presently considered to be essential, they are identified as such.

[0063]It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Moreover, although the term “step” can be used herein to connote different aspects of methods employed, the term should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly required. Further, the disclosed technology does not necessarily require all steps included in the methods and processes described herein. That is, the disclosed technology includes methods that omit one or more steps expressly discussed with respect to the methods described herein.

[0064]It should be apparent that the foregoing relates only to certain embodiments of the present disclosure and that numerous changes and modifications may be made herein by one of ordinary skill in the art without departing from the general spirit and scope of the disclosure.

[0065]Although specific embodiments of the disclosure have been described, numerous other modifications and alternative embodiments are within the scope of the disclosure. For example, any of the functionality described with respect to a particular device or component may be performed by another device or component. Further, while specific device characteristics have been described, embodiments of the disclosure may relate to numerous other device characteristics. Further, although embodiments have been described in language specific to structural features and/or methodological acts, it is to be understood that the disclosure is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as illustrative forms of implementing the embodiments. Conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments could include, while other embodiments may not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments.