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United States Patent Application	20060052048
Kind Code	A1
Poirier; Bertrand	March 9, 2006

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Foreign Application Data

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Date	Code	Application Number
Apr 27, 2004	CA	2,464,547

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Claims

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1. An adaptable modular assembly for use in a heating, ventilation and air conditioning (HVAC) unit comprising: a) a modular frame having at least one or more apertures located on an outer surface of the modular frame; b) at least one or more plate members positioned on one or more of the apertures; c) at least one or more channel members positioned in the modular frame; d) at least one or more motors positioned within the modular frame wherein the motors enable air to enter and exit the apertures located on the outer surfaces of the modular frame; and e) a restrictor plate which isolates the motors within the modular frame.

2. The adaptable modular assembly of claim 1, wherein the at least one or more apertures on the modular frame further comprises at least one fresh air intake aperture and at least one fresh air outlet aperture.

3. The adaptable modular assembly of claim 2, wherein the at least one or more apertures on the modular frame further comprises at least one stale air intake aperture and at least one stale air outlet aperture.

4. The adaptable modular assembly of claim 3, wherein the at least one or more plate members positioned on one or more of the apertures are detachably removable.

5. The adaptable modular assembly of claim 3, wherein the at least one or more channel members positioned in the modular frame further comprises a fresh air transfer channel for transferring fresh air from an outside source to an interior building or dwelling.

6. The adaptable modular assembly of claim 5, wherein the at least one or more channel members positioned in the modular frame further comprises a stale air transfer channel for transferring stale air from the interior building or dwelling to the outside source.

7. The adaptable modular assembly of claim 6, wherein the modular frame further comprises at least one heat recovery module therein.

8. The adaptable modular assembly of claim 7, wherein the at least one or more motors further comprises at least one intake opening and at least one outlet opening, whereby the at least one intake opening cooperatively transfers fresh air received from the at least one fresh air intake aperture on the modular frame along and through the fresh air transfer channel, the fresh air then being transferred from the fresh air transfer channel through the at least one outlet opening in the at least one or more motors, and then through the at least one fresh air outlet aperture on the modular frame to the interior building or dwelling.

9. The adaptable modular assembly of claim 8, wherein the at least one intake opening and at least one outlet opening of the at least one or more motors are positioned on an outer surface of the at least one or more motors.

10. The adaptable modular assembly of claim 9, wherein stale air from the interior building or dwelling is drawn through the at least one stale air intake aperture on the modular frame and into the at least one intake opening of the at least one or more motors, whereby the at least one intake opening cooperatively transfers stale air received from the at least one stale air intake aperture on the modular frame along and through the stale air transfer channel, the stale air then being transferred from the stale air transfer channel through the at least one outlet opening in the at least one or more motors, and then through the at least one stale air outlet aperture on the modular frame to the outside source.

11. The adaptable modular assembly of claim 10, wherein the at least one or more motors are rotatably repositionable within the modular frame.

12. The adaptable modular assembly of claim 11, wherein the stale air transfer channel and the fresh air transfer channel are in perpendicular relation to one another within the modular frame.

13. An adaptable modular assembly for use in a heating, ventilation and air conditioning (HVAC) unit comprising: a) a modular frame; b) at least one fresh air intake aperture and at least one fresh air outlet aperture located on an outer surface of the modular frame; c) at least one stale air intake aperture and at least one stale air outlet aperture located on the outer surface of the modular frame; d) at least one or more channel members positioned in the modular frame; e) at least one or more motors positioned within the modular frame wherein the motors enable fresh air to enter at least one fresh air intake aperture and exit the at least one fresh air outlet aperture, and wherein the at least one or more motors also enable stale air to enter the at least one stale air intake aperture and exit the at least one stale air outlet aperture; and f) a restrictor plate which isolates the one or more motors within the modular frame.

14. The adaptable modular assembly of claim 13, wherein the modular frame further comprises at least one heat recovery module therein.

15. The adaptable modular assembly of claim 14, wherein the at least one or more plate members positioned on one or more of the apertures are detachably removable.

16. The adaptable modular assembly of claim 15, wherein the at least one or more plate members are placed to restrict air flow through each of only one fresh air intake aperture and one fresh air outlet, and through each of only one stale air intake aperture and one stale air outlet aperture.

17. An adaptable modular assembly for use in a heating, ventilation and air conditioning (HVAC) unit comprising: a) a modular frame; b) at least one fresh air intake aperture and at least one fresh air outlet aperture located on an outer surface of the modular frame; c) at least one stale air intake aperture and at least one stale air outlet aperture located on the outer surface of the modular frame; d) at least one or more channel members positioned in the modular frame, the at least one or more channel members defining a fresh air transfer channel for transferring fresh air from an outside source to an interior building or dwelling and a stale air transfer channel for transferring stale air from the interior building or dwelling to the outside source, the fresh air channel and the stale air channel being separate from one another; e) at least one or more motors positioned within the modular frame, the at least one or more motors having at least one intake opening and at least one outlet opening; f) at least one heat recovery module, the at least one heat recovery module having at least one intake opening and at least one outlet opening; and g) a restrictor plate which isolates the one or more motors within the modular frame, whereby the at least one intake opening cooperatively transfers fresh air received from the at least one fresh air intake aperture on the modular frame through the at least one intake opening of the at least one or more motors, and along and through the fresh air transfer channel, the fresh air then being transferred from the fresh air transfer channel through the at least one intake opening in the at least one heat recovery module, and then through the at least one outlet opening in the at least one heat recovery module, where the fresh air is then directed through the at least one fresh air outlet aperture on the modular frame to the interior building or dwelling, and whereby stale air from the interior building or dwelling is drawn through the at least one stale air intake aperture on the modular frame and into the intake opening of the at least one heat recovery module, whereby the at least one intake opening of the at least one heat recovery module cooperatively transfers stale air received from the at least one stale air intake aperture on the modular frame along and through the stale air transfer channel, the stale air then being transferred from the stale air transfer channel through the at least one outlet opening in the at least one or more motors, and then through the at least one stale air outlet aperture on the modular frame to the outside source.

18. The adaptable modular assembly of claim 17, wherein the modular frame further comprises a plurality of apertures.

19. The adaptable modular assembly of claim 18, wherein, when any of the plurality of apertures are not to be used, the apertures not to be used are covered with at least one or more plate members which are positioned thereon.

20. The adaptable modular assembly of claim 19, wherein the at least one or more plate members positioned on the apertures not to be used are detachably removable.

21. The adaptable modular assembly of claim 20, wherein the at least one or more motors are rotatably repositionable within the modular frame.

22. The adaptable modular assembly of claim 21, wherein the at least one or more motors is positioned on a rail mechanism which allows it to slide from within the HVAC unit, the rail mechanism being secured to an interior surface of the HVAC unit.

23. The adaptable modular assembly of claim 22, wherein the at least one heat recovery module is positioned on a rail mechanism which allows it to slide from within the HVAC unit, the rail mechanism being secured to an interior surface of the HVAC unit.

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Description

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FIELD OF THE INVENTION

[0001] The present invention pertains to the field of modular assemblies and more specifically to modular assemblies for use with HVAC (heating, ventilation and air conditioning) units.

BACKGROUND

[0002] The use of heating, ventilation and air conditioning units are increasing as certain breakthroughs have enabled manufacturers to design and produce such units more efficiently, thereby potentially reducing the cost to consumers, for example. A common drawback to the use of HVAC units is the noise and vibrations generated by the motors, which may subsequently be transmitted throughout the unit. Such noise and vibrations are typically unappealing to consumers and attempts have been made to reduce such problems.

[0003] Furthermore, given the modular design of present HVAC units, certain applications cannot properly utilize or install the modular unit given the location of the intake and/or exhaust. General, conventional modular designs in the HVAC industry have the intake and exhaust apertures for fresh air and stale air opposite to one another.

[0004] Therefore, there is a need for an adaptable modular HVAC assembly, wherein the intake and exhaust apertures of the HVAC unit can be modified to facilitate the installation and proper operation thereof in various buildings or dwellings. In other words, there is a need for an HVAC unit wherein the intake and exhaust apertures of the HVAC unit can be manipulated, as necessary, to facilitate the installation of the HVAC unit, and thus accommodate nuances and variations between various buildings.

[0005] This background information is provided for the purpose of making known information believed by the applicant to be of possible relevance to the present invention. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art against the present invention.

SUMMARY OF THE INVENTION

[0006] An object of the present invention is to provide an adaptable modular HVAC assembly for use in adapting the intake and exhaust of air from a heating, ventilation and air conditioning (HVAC) unit containing motors.

[0007] According to another object of the present invention, there is provided an improved adaptable modular HVAC assembly wherein the intake and exhaust apertures of the HVAC unit can be manipulated, as necessary, to facilitate the proper installation of the HVAC unit in different types of buildings. Of course, such manipulation of the intake and exhaust apertures increases the adaptability of the present modular assembly to accommodate installation of the HVAC unit in buildings having varying floor plans and structures.

[0008] A still further object of the present invention is to provide an improved adaptable modular HVAC assembly wherein the interchangeability of the air flow through the adaptable modular HVAC assembly is achieved through modifications of the intake and exhaust apertures and air flow channels, the apertures and channels being modified through the use of channel or plate members.

[0009] A still further object of the present invention provides for an improved adaptable modular HVAC assembly which provides quick access and maintenance of the motors or filtration assembly of the HVAC assembly.

[0010] According to one aspect of the present invention, there is provided an adaptable modular assembly for use in a heating, ventilation and air conditioning (HVAC) unit comprising a) a modular frame having at least one or more apertures located on the outer surface of the modular frame; b) at least one or more plate members positioned on one or more of the apertures; c) at least one or more channel members positioned in the modular frame; d) at least one or more motors positioned within the modular frame wherein the motors enable air to enter and exit the apertures located on the outer surfaces of the modular frame; and e) a restrictor plate which isolates the motors within the modular frame.

[0011] According to another aspect of the present invention, there is provided an adaptable modular assembly for use in a heating, ventilation and air conditioning (HVAC) unit comprising (a) a modular frame; (b) at least one fresh air intake aperture and at least one fresh air outlet aperture located on an outer surface of the modular frame; (c) at least one stale air intake aperture and at least one stale air outlet aperture located on the outer surface of the modular frame; (d) at least one or more channel members positioned in the modular frame; (e) at least one or more motors positioned within the modular frame wherein the motors enable fresh air to enter at least one fresh air intake aperture and exit the at least one fresh air outlet aperture, and wherein the at least one or more motors also enable stale air to enter the at least one stale air intake aperture and exit the at least one stale air outlet aperture; and (f) a restrictor plate which isolates the one or more motors within the modular frame.

[0012] Yet another aspect of the present invention provides for an adaptable modular assembly for use in a heating, ventilation and air conditioning (HVAC) unit comprising (a) a modular frame; (b) at least one fresh air intake aperture and at least one fresh air outlet aperture located on an outer surface of the modular frame; (c) at least one stale air intake aperture and at least one stale air outlet aperture located on the outer surface of the modular frame; (d) at least one or more channel members positioned in the modular frame, the at least one or more channel members defining a fresh air transfer channel for transferring fresh air from an outside source to an interior building or dwelling and a stale air transfer channel for transferring stale air from the interior building or dwelling to the outside source, the fresh air channel and the stale air channel being separate from one another; (e) at least one or more motors positioned within the modular frame, the at least one or more motors having at least one intake opening and at least one outlet opening; (f) at least one heat recovery module, the at least one heat recovery module having at least one intake opening and at least one outlet opening; and (g) a restrictor plate which isolates the one or more motors within the modular frame, whereby the at least one intake opening cooperatively transfers fresh air received from the at least one fresh air intake aperture on the modular frame through the at least one intake opening of the at least one or more motors, and along and through the fresh air transfer channel, the fresh air then being transferred from the fresh air transfer channel through the at least one intake opening in the at least one heat recovery module, and then through the at least one outlet opening in the at least one heat recovery module, where the fresh air is then directed through the at least one fresh air outlet aperture on the modular frame to the interior building or dwelling, and whereby stale air from the interior building or dwelling is drawn through the at least one stale air intake aperture on the modular frame and into the intake opening of the at least one heat recovery module, whereby the at least one intake opening of the at least one heat recovery module cooperatively transfers stale air received from the at least one stale air intake aperture on the modular frame along and through the stale air transfer channel, the stale air then being transferred from the stale air transfer channel through the at least one outlet opening in the at least one or more motors, and then through the at least one stale air outlet aperture on the modular frame to the outside source.

[0013] The advantage of the present invention is that it provides an adaptable modular HVAC assembly for use in adapting the intake and exhaust of air from a heating, ventilation and air conditioning (HVAC) unit containing motors.

[0014] Yet another advantage of the present invention is that it provides an improved adaptable modular HVAC assembly wherein the intake and exhaust apertures of the HVAC unit can be manipulated, as necessary, to facilitate the proper installation of the HVAC unit in different types of buildings.

[0015] A still further advantage of the present invention is that it provides an improved adaptable modular HVAC assembly which provides quick access and maintenance of the motors or filtration assembly of the HVAC assembly.

BRIEF DESCRIPTION OF THE FIGURES

[0016] FIG. 1 is a side perspective view showing the location of apertures according to one embodiment of the present invention;

[0017] FIG. 2 is another side perspective view showing the location of apertures on the modular frame member according to one embodiment of the present invention;

[0018] FIG. 3 is a side view of an HVAC unit showing the location of the impellers of the motor and the air flow within the HVAC assembly according to one embodiment of the present invention;

[0019] FIG. 3a is a back view of an HVAC unit showing the air flow within the air channels of the HVAC assembly according to one embodiment of the present invention;

[0020] FIG. 3b is a side view of an HVAC unit showing the filtration location and the air flow within the HVAC assembly according to one embodiment of the present invention; and

[0021] FIG. 4 is another side view of an HVAC unit showing the location of the impellers of the motor and the air flow within the HVAC assembly according to one embodiment of the present invention; and

[0022] FIG. 5 is an exploded view of the components of the HVAC unit, according to one embodiment of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0023] The present invention provides a modular frame assembly for facilitating the installation and increasing applications which use HVAC units. The modular frame of the present invention provides the ability to modify the air channels commonly utilized in an HVAC unit, and, through the modification of these air channels which encompasses intake and exhaust apertures, HVAC units can be installed in cramped spaces. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

[0024] In one embodiment of the present invention and with reference to FIG. 1, the modular frame member 10 provides for intake apertures 20 and exhaust apertures 30 which are located on the vertical surface 40 of the modular frame member 10. Of course, it is to be understood that the term "Modular Frame Member" is used to define the physical shell which encompasses the other elements of the present invention. In a preferred embodiment, the modular frame member 10 has numerous apertures located on the outer surface thereof. The number of apertures present on the modular frame member 10 increases the versatility of an HVAC, as hereinafter described. The modular frame member 10 is generally composed of steel or any other material as would be known by a worker skilled in the relevant art, though it is conceivable that other types of material could be used, provided that the required material should have the required tensile strength to support motors commonly used in the field of HVAC units. With further reference to FIG. 1, a worker skilled in the relevant art would be familiar with the use of two intake apertures such that there is a fresh air intake and a stale air intake. A worker skilled in the relevant art would also be familiar with the use of at least two exhaust apertures within an HVAC unit such that there is a fresh air exhaust and stale air exhaust.

[0025] As noted above, the modular frame member 10 has numerous apertures (for either intake or exhaust) located on the outer surface thereof. These apertures, in a preferred embodiment, are pre-cut in the modular frame member so as to establish the location of the intake and exhaust apertures. Furthermore, the present invention provides that the intake and exhaust apertures on the modular frame member 10 of the HVAC unit can be manipulated, as necessary, to facilitate the proper installation of the HVAC unit in different types of buildings. Of course, such manipulation of the intake and exhaust apertures increases the adaptability of the present modular assembly to accommodate installation of the HVAC unit in buildings having varying floor plans and structures.

[0026] To manipulate the layout of the intake and exhaust apertures, it should be noted that any of the pre-cut intake or exhaust apertures that are not to be used are to be covered with plate members 55, as can be seen with reference to FIG. 5, it being understood that the term "plate member" is used to define a member positioned on the outer surface of the modular frame member 10 in order to modify the location of the apertures present on the modular frame member. Of course, the use of such plate members allows concealment of the pre-cut apertures in the modular frame member and establishes the location of the intake and exhaust apertures which are to be used. In this manner, the use of such plate members enables modification of the apertures located on the modular frame member wherein, for example, all apertures can be located on a specific surface or wherein, in another example, an identical number of apertures can be positioned on opposite surfaces of the modular frame member 10.

[0027] In one embodiment of the present invention and with reference to FIG. 5, the use of channel members 69 further enables the control of the air flow within an HVAC unit having the modular frame of the present assembly, it being understood that the term "Channel Member" is used to define a member located within the modular frame member 10 which establish the travel of air through channels within the modular frame member 10, once the components of the present assembly are placed together, and exploded view of which can be seen with reference to FIG. 5. The channel members 69 are required to direct the air to the apertures (not shown) located on the outer surface of the modular frame member 10. In one embodiment of the present invention, the channel member is simply a flat piece of metal or aluminum which restricts and defines the air channels within the modular frame member 10, though it is conceivable that other types of material could be contemplated. Of course, it would be readily apparent to one skilled in the art that, through manipulation of the placement of the channel members, in conjunction with manipulation of the intake and exhaust apertures of the HVAC unit, as necessary, the modular HVAC assembly of the present invention can be adapted to facilitate the proper installation of the HVAC unit in different types of buildings.

[0028] In one embodiment of the present invention, and with reference to FIG. 2, the modular frame member 10 has the intake apertures 20 on a first vertical surface 50 of the modular frame and the exhaust apertures 30 on a second vertical surface of the modular frame 10.

[0029] In one embodiment of the present invention and with reference to FIGS. 3, 3a 3b and 4 the impellers 60 and 70 of the motor module within an HVAC unit are located opposite to one another. The impellers 60 and 70 of the motor module are located on the same side of the HVAC unit and the core (such as a heat recovery module) 61 is positioned on the opposite side of the impellers 60 and 70 of the motor module, as can be seen with reference to FIG. 5. In this manner, the impellers 60 and 70 of the motor module are positioned within a structure that allows the retrieval of the impeller structure (the motor module) from within the HVAC unit. In a preferred embodiment, the fresh air intake 80 enables air introduced into the HVAC unit to travel within the HVAC unit as defined by the path shown through arrows 1-6. The stale air exhaust 90 enables the air to travel within the HVAC unit as defined by the path shown through the use of arrows 7-12. A restrictor plate 100 isolates both impellers 60 and 70 of the motor module from one another, and a divider baffle 71 can also be used to guide internal airflow as required.

[0030] As noted above, and with reference to FIGS. 3 and 4, fresh air is introduced into the HVAC unit through intake apertures 20 (not shown) on the outside of the modular frame member 10. As the fresh air is brought into (1) the HVAC unit, through the fresh air intake 80, the fresh air is then introduced (2) through the impeller 60 of the HVAC unit, where it is routed (3) via the restrictor plate 100 to the fresh air transfer channel 63. With reference to FIG. 3a, the fresh air travels within the HVAC unit as defined by arrow (4), passing along and through the core (such as a heat recovery module) 61 as it goes, it being understood that the core may have openings therein to allow such airflow to occur. With reference to FIG. 3b, the fresh air is then routed (5) through an opening in the core or the filtration device of the HVAC unit (such as a heat recovery module) 61, 6 wherein it is then introduced (6) into the house, building or dwelling through the fresh air exhaust 110.

[0031] With reference to FIG. 3b, stale air is introduced (7) into the HVAC unit through intake apertures 20 (not shown) on the outside of the modular frame member 10, where it is then routed (8) through an opening in the core or the filtration device of the HVAC unit (not shown) to, with reference to FIG. 4, the stale air transfer channel 67, wherein the stale air travels within the HVAC unit as defined by arrow (9) in FIG. 3a. With reference to FIG. 3, the stale air is then drawn (10) through the second impeller 70 of the HVAC unit, where it is routed (11) via the restrictor plate 100 beyond the 16 HVAC unit to an outside source (12).

[0032] As can be seen with reference to FIG. 3a, the stale air intake also allows the stale air travelling in the stale air transfer channel 67 to travel perpendicular to the fresh air travelling in the fresh air transfer channel 63 within the core or filtration device of the HVAC according to one embodiment of the present invention. In a preferred embodiment, the impeller structure is positioned on a rail mechanism which allows it to slide from within the HVAC assembly. In a further embodiment of the present invention, the core which is adjacent to the impeller structure is also on a similar rail mechanism which also allows the retrieval from within the HVAC assembly. The use of a rail mechanism allows for quick maintenance of the impellers and the core, if required, from within the HVAC unit.

[0033] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.

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