Roof assembly for an air handler

• US 8,282,452 B2
• Filed: 11/06/2008
• Issued: 10/09/2012
• Est. Priority Date: 11/06/2008
• Status: Active Grant

• Current Assignee: Trane International Inc. (Trane Technologies plc)
• Original Assignee: Trane International Inc. (Trane Technologies plc)
• Inventors: Grigsby, James M., Marks, Jeffrey C.
• Primary Examiner(s): Keasel, Eric
• Assistant Examiner(s): Morales, David Colon
• Application Number:
  US12/291,123
• Publication Number:
  US 20100112930A1
• Time in Patent Office: 1,433 Days
• Field of Search: 248/317, 248/581, 494/63, 220796-806, 62/77, 622/95, 622/98, 454/333
• US Class Current: 454/333
• CPC Class Codes: F24F 13/20 Casings or covers
• CPC Class Codes: F24F 2221/36 Modules, e.g. for an easy mounting or transport
• CPC Class Codes: F24F 3/0442 with volume control at a constant temperature

Abstract

An air handler (or air handler section) includes an enclosure containing various internal HVAC components and a bi-directional alignment system that during factor assembly of the enclosure helps align the enclosure'"'"'s entire roof to the internal components. To help align the roof in a widthwise direction, a tapered lead-in edge in the upper corners of a block-off panel for an evaporator, filter rack, damper, fan and/or other HVAC component engages a roof rail that runs along the length of the roof. The upper corners of the block-offs also include a landing edge that engages the underside of the roof rail to help support the weight of the roof. Cross rails attached to the underside of the roof and extending along the width of the enclosure include an inclined lead-in flange that engages the upper edge of the various internal HVAC components, thereby helping align the roof in a lengthwise direction.

Claims

1. An air handler having a length, width and a height, the air handler comprising:

a heat exchanger containing a fluid;

an internal panel extending along the width of the air handler, the internal panel includes an upper corner having a landing edge and a lead-in edge, wherein the landing edge extends horizontally and the lead-in edge is at an incline;

a roof rail running along the length of the air handler and being above the landing edge of the internal panel;

a side panel underneath the roof rail and adjacent the internal panel;

a roof above the side panel, above the heat exchanger, and being supported by the side panel and the roof rail;

a gap at the upper corner of the internal panel, the gap is defined by the lead-in edge of the internal panel, the roof rail, and the roof; and

a gasket that at least partially fills the gap.

2. The air handler of claim 1, wherein the gasket is compressed between the roof and the internal panel.

3. The air handler of claim 1, wherein the gap is generally triangular.

4. The air handler of claim 1, wherein the internal panel is a block-off extension of the evaporator.

5. The air handler of claim 1, further comprising a filter rack underneath the roof, wherein the internal panel is a block-off extension of the filter rack.

6. The air handler of claim 1, further comprising a damper underneath the roof, wherein the internal panel is a block-off extension of the damper.

7. The air handler of claim 1, further comprising a fan underneath the roof, wherein the internal panel is a block-off extension of the fan.

8. The air handler of claim 1, further comprising:

a first cross rail attached to the roof and being elongate along the width of the air handler, the first cross rail includes a first lead-in flange that lies at an incline; and

a second cross rail attached to the roof and being elongate along the width of the air handler, the second cross rail includes a second lead-in flange that lies at an incline, the internal panel is interposed between the first cross rail and the second cross rail, the first lead-in flange and the second lead-in flange flare away from the internal panel.

9. The air handler of claim 8, further comprising a gasket between the first cross rail and the second cross rail and being compressed between the roof and the internal panel.

10. The air handler of claim 9, wherein the gasket substantially fills the gap.

11. The air handler of claim 1, wherein the landing edge is substantially horizontal.

12. An air handler having a length, width and a height, the air handler comprising:

a heat exchanger containing a fluid;

an internal panel extending along the width of the air handler, the internal panel includes an upper corner;

a roof rail running along the length of the air handler and being adjacent the upper corner of the internal panel;

a side panel underneath the roof rail and adjacent the internal panel;

a roof above the side panel, above the heat exchanger, and being supported by the side panel and the roof rail;

a first cross rail attached to the roof and being elongate along the width of the air handler, the first cross rail includes a first lead-in flange that lies at an incline; and

a second cross rail attached to the roof and being elongate along the width of the air handler, the second cross rail includes a second lead-in flange that lies at an incline, the internal panel is interposed between the first cross rail and the second cross rail, the first lead-in flange and the second lead-in flange flare away from the internal panel.

13. The air handler of claim 12, wherein the internal panel is a block-off extension of the evaporator.

14. The air handler of claim 12, further comprising a filter rack underneath the roof, wherein the internal panel is a block-off extension of the filter rack.

15. The air handler of claim 12, further comprising a damper underneath the roof, wherein the internal panel is a block-off extension of the damper.

16. The air handler of claim 12, further comprising a fan underneath the roof, wherein the internal panel is a block-off extension of the fan.

17. The air handler of claim 16, further comprising a gasket between the first cross rail and the second cross rail and being compressed between the roof and the internal panel.

18. An air handler having a length, width and a height, the air handler comprising:

a heat exchanger containing a fluid;

a fan forcing air through the heat exchanger;

an internal panel extending along the width of the air handler, the internal panel includes an upper corner having a landing edge and a lead-in edge, wherein the landing edge extends horizontally and the lead-in edge is at an incline;

a roof rail running along the length of the air handler and being above the landing edge of the internal panel;

a side panel underneath the roof rail and adjacent the internal panel;

a roof above the side panel, above the heat exchanger, and being supported by the side panel and the roof rail;

a gap at the upper corner of the internal panel, the gap is defined by the lead-in edge of the internal panel, the roof rail, and the roof;

a gasket that at least partially fills the gap;

a first cross rail attached to the roof and being elongate along the width of the air handler, the first cross rail includes a first lead-in flange that lies at an incline; and

a second cross rail attached to the roof and being elongate along the width of the air handler, the second cross rail includes a second lead-in flange that lies at an incline, the internal panel is interposed between the first cross rail and the second cross rail, the first lead-in flange and the second lead-in flange flare away from the internal panel.

19. The air handler of claim 18, wherein the gasket is compressed between the roof and the internal panel.

20. The air handler of claim 18, wherein the gap is generally triangular.

21. The air handler of claim 18, wherein the internal panel is a block-off extension of the evaporator.

22. The air handler of claim 18, further comprising a filter rack underneath the roof, wherein the internal panel is a block-off extension of the filter rack.

23. The air handler of claim 18, further comprising a damper underneath the roof, wherein the internal panel is a block-off extension of the damper.

24. The air handler of claim 18, wherein the internal panel is a block-off extension of the fan.

25. The air handler of claim 18, wherein the gasket that at least partially fills the gap also extends between the first cross rail and the second cross rail and is compressed between the roof and the internal panel.

26. The air handler of claim 18, wherein the landing edge is substantially horizontal.