Modular Bulkhead System
A structural support system for a fan array system. The system allows for a modular bulkhead wall to be customized and installed within a cabinet of an air handling unit. The modular bulkhead wall comprises one or more intermediate bulkhead stiffening elements that enable the modular bulkhead wall to support the fan array system.
This application is a continuation of U.S. patent application Ser. No. 16/908,127, filed Jun. 22, 2020, which claims priority to U.S. provisional patent application Ser. No. 62,837,018, filed Apr. 22, 2019, each of which is incorporated by reference in its entirety herein.
FIELD OF THE INVENTIONThe present invention relates to a modular bulkhead system that can be utilized in the HVAC industry. The modular bulkhead system may be installed in new air handling units as well as within existing air handling units.
PRIOR ARTTraditionally, replacing a malfunctioning fan system within an air handling unit often requires removal and replacement of the entire air handling unit. Air handling units are housed in cabinets that often weigh significantly more than the typical person can lift. Furthermore, deconstructing an already existing air handler unit to facilitate removal without a crane does not overcome the challenge of lifting and positioning its replacement. As such, removal and replacement of an already existing air handling unit often requires use of a crane, which can increase costs substantially. Additionally, retrofitting new equipment, such as a new fan system, within the cabinet of an already existing air handling unit is often limited by size of the cabinet doors as well as confined space within the cabinet. A more economical and effective solution for replacing a malfunctioning fan system within an already existing air handing unit is needed.
BRIEF SUMMARY OF THE INVENTIONThe present invention provides a unique and novel modular bulkhead system for retrofitting an already existing air handling unit with a new fan array as well as for installing new fan arrays within original equipment manufacturing of new air handling units. Typically, the process of replacing a commercial fan system within an air handling unit is extremely expensive because the entire air handling unit must be removed, and a new air handling unit must be installed in its place. It is not uncommon for this process to require a crane to lift the entire air handler from its location and then placing the new air handler in its place. With the presently described invention, a crane would not be needed to replace a commercial fan system.
This invention allows removal of the old fan system and retrofitting the new fan system in a modular fashion such that each piece to the new fan system can be installed within an already existing air handler. This is accomplished with the unique and novel modular bulkhead system, which provides a bulkhead wall comprised of a plurality of panels that each may be hand carried and installed by one individual within a cabinet housing an air handling unit. The modular bulkhead system further provides a structural frame that is directly attached to the interior of the cabinet. Each panel of the plurality of panels is supported by the structural frame. Once the plurality of panels is installed, a plurality of fans may then be attached to the bulkhead wall at predetermined locations and subsequently connected to the power and control system. Retrofitting an already existing air handling unit with the modular bulkhead system can provide substantial cost savings relative to replacing the already existing air handling unit with an entirely new air handling unit.
In one aspect an HVAC modular bulkhead system for support of one or more suspended fans includes a modular bulkhead wall, wherein the modular bulkhead wall further includes a plurality of interlocking vertical panels. The plurality of interlocking vertical panels are aligned side-by-side substantially perpendicular to the longitudinal direction of an airstream. The one or more suspended fans produce the airstream in the longitudinal direction. The plurality of interlocking vertical panels further include a first side panel, a second side panel, and at least one middle panel. The at least one middle panel is configured as a fan panel, the fan panel includes at least one panel opening, and the fan panel is configured to support attachment of one or more of the suspended fans. The first side panel provides a frame attachment end and a stiffening flange, the second side panel provides a frame attachment end and a c-channel, and the at least one middle panel provides a stiffening flange and a c-channel. The stiffening flange of the first side panel interlocks and attaches with the c-channel of the at least one middle panel, and the stiffening flange of the at least one middle panel interlocks and attaches with the c-channel of the second side panel. A tubular intermediate bulkhead stiffening element is formed by the interlocking and attachment of the stiffening flange and the c-channel of adjacent panels.
In another aspect an HVAC modular bulkhead system for support of one or more suspended fans includes a modular bulkhead wall, wherein the modular bulkhead wall further includes a plurality of interlocking vertical panels. The plurality of interlocking vertical panels are aligned side-by-side substantially perpendicular to the longitudinal direction of an airstream. The one or more suspended fans produce the airstream in the longitudinal direction. The plurality of interlocking vertical panels further include a first side panel, a second side panel, and at least one middle panel. The at least one middle panel is configured as a fan panel, the fan panel includes at least one panel opening, and the fan panel is configured to support attachment of one or more of the suspended fans. The first side panel provides a frame attachment end and a stiffening flange, the second side panel provides a frame attachment end and a c-channel, and the at least one middle panel provides a stiffening flange and a c-channel. The stiffening flange of the first side panel interlocks and attaches with the c-channel of the at least one middle panel, and the stiffening flange of the at least one middle panel interlocks and attaches with the c-channel of the second side panel. An intermediate bulkhead stiffening element is formed by the interlocking and attachment of the stiffening flange and the c-channel of adjacent panels. The HVAC modular bulkhead system for support of one or more suspended fans also includes one or more fans. The one or more fans each has an integrally attached fan plate. During suspension of the one or more integrally attached fan and fan plate on the fan panel, the fan plate covers the at least one fan panel opening and is attached thereto and provides support for suspension of the at least one fan from the at least one fan panel.
In further aspect a method of installing an HVAC modular bulkhead system for support of one or more suspended fans within an air handling unit cabinet includes obtaining the HVAC modular bulkhead system of the previous aspect. The method includes positioning the plurality of interlocking vertical panels to be aligned side-by-side substantially perpendicular to the longitudinal direction of the suspended fan airstream. The method also includes attaching the frame attachment end of the first side panel to a frame of the cabinet and securing the top and bottom ends of the first side panel to the frame of the cabinet. The method also includes attaching the c-channel of the at least one middle panel to the stiffening flange of the first side panel and securing the top and bottom ends of the at least one middle panel to the frame of the cabinet. The method also includes attaching the c-channel of the second side panel to the stiffening flange of the at least one middle panel, attaching the frame attachment end of the second side panel to a frame of the cabinet, and securing the top and bottom ends of the second side panel to the frame of the cabinet, thereby forming the modular bulkhead wall. The method further includes suspending each of the one or more integrally attached fan and fan plate on each of the fan panels such that the fan plate covers the at least one fan panel opening, and attaching each of the fan plates to the fan panels, thereby supporting suspension of each of the at least one fan from the at least one fan panel.
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- 5—Modular bulkhead system
- 6—Fan
- 7—Fan plate
- 8—Panel opening
- 9—Bulkhead door
- 10—First side panel
- 15—Fan panel
- 20—Second side panel
- 25—Filler panel
- 30—Structural frame
- 31—Transition frame
- 35—Fastener
- 40—Pre-punched hole
- 45—C-channel
- 46—C-channel lip
- 47—Stiffening flange
- 50—Flange
- 55—Nut-insert
- 60—Ledge
- 65—Quick-connect box
- 80—Cabinet
- 81—Cabinet door
- 110—Alternative first side panel
- 120—Alternative second side panel
A non-limiting exemplary embodiment of the present invention provides a modular bulkhead system 5 that is installed within the airstream of an air handling unit and is capable of supporting an array of one or more fans 6. The modular bulkhead system 5 provides a modular bulkhead wall that supports the array of fans such that they can be easily and cost effectively retrofitted within a cabinet 80. The modular bulkhead wall provides a front surface and a back surface. It is anticipated that the cabinet 80 is provided for an already existing air handling unit or a new air handling unit during its original equipment manufacture. This modular bulkhead system 5 is useful when retrofitting the already existing air handling unit because the cabinet 80, which encloses the air handling unit, restricts access to its interior such that retrofitting a new fan system is not typically possible without also retrofitting the cabinet 80. Accordingly, once a malfunctioning fan system is removed from the already existing air handling unit, each component of the modular bulkhead system 5 can be hand carried by one person into the cabinet 80 to then be installed. As such, the already existing air handling unit may be salvaged, resulting in a plurality of benefits that include a significant cost savings for installation and repair. A non-limiting example of such cost savings is, this modular bulkhead system 5 allows for an individual to install the modular bulkhead system 5 from the front side of the modular bulkhead wall, thereby further reducing time of installation. Consequently, the modular bulkhead system 5 can be customized for virtually any air handling unit within the HVAC industry while maintaining the same or similar method of installation.
The modular bulkhead system 5 provides a modular bulkhead wall as well as a structural frame 30 or a transition frame 31. The structural frame 30 comprises a plurality of structural frame members. Each structural frame member of the plurality of structural frame members comprises a first leg and a second leg that are integrally attached to one another and form a substantially L-shaped cross-sectional profile. The first leg of each structural member attaches directly to an interior cabinet surface, as shown in
The first non-limiting exemplary embodiment of the modular bulkhead wall comprises a plurality of panels including at least one middle panel, a first side panel 10, and a second side panel 20. The middle panel(s) may comprise a fan panel 15 or a filler panel 25. The fan panel 15 is configured to support hanging attachment of one or more of the suspended fans 6.
The modular nature of the panels allows for various alternative bulkhead walls to be assembled to coordinate with each custom application. One example application is where the frame attachment along each side edge of the bulkhead wall provides sufficient vertical structural support to the side panels such that they do not require additional vertical stiffening support. The alternate second non-limiting exemplary embodiment of the modular bulkhead wall, shown schematically in
The first non-limiting exemplary modular bulkhead wall is represented in
As described above and as shown in the
Each panel provided by the modular bulkhead wall provides either a c-channel 45, a stiffening flange 47, or both. Additionally, the first side panel 10 provides one stiffening flange 47, the second side panel 20 provides one c-channel 45, and the fan panel 15 and filler panel 25 each provide one stiffening flange 47 and one c-channel 45, as shown in
Further, as best seen in
The modular nature of the panels provides for further alternatives to be assembled to meet the custom requirements of each application. For example, in the modular bulkhead wall depicted in
The c-channel 45 and stiffening flange 47 are integrally attached to the panels which they are respectively provided by. The c-channel 45 and the stiffening flange 47 each respectively span from substantially the top of the modular bulkhead wall to substantially the bottom of the modular bulkhead wall, as shown in
Installation of the modular bulkhead system 5 requires the plurality of structural frame members of the structural frame 30 to be attached to interior surfaces within the cabinet 80. The structural frame 30 is preferably affixed to the cabinet 80 with a plurality of fasteners 35, as shown in
When retrofitting the modular bulkhead system 5 within an already existing air handling unit, the modular bulkhead wall attaches directly to the structural frame 30, as shown in
The transition frame 31 comprises a plurality of transition frame members. Each transition frame member of the plurality of transition frame members provides a first flange and a second flange. The first flange and second flange are integrally attached to each other and provide a substantially L-shaped cross-sectional profile. The first flanges of the transition frame 31 are substantially parallel to the first legs of the structural frame 30. The second flanges of the transition frame 31 attach to both the modular bulkhead wall and the second legs of the structural frame 30, as shown in
The transition frame 31 offers additional installation tolerances that are not afforded when directly connecting the bulkhead wall to the structural frame 30. Additionally, some installations of the modular bulkhead system 5 allow for the modular bulkhead wall to be preassembled prior to transporting the modular bulkhead wall to the air handling unit that it will be installed within. As such, attaching a transition frame 31 to a preassembled modular bulkhead wall prior to transporting the preassembled modular bulkhead wall offers several benefits, such as improved structural rigidity of the preassembled modular bulkhead wall during transport as well as improved efficiency during installation of the modular bulkhead system 5 within the cabinet 80. Furthermore, when the modular bulkhead system 5 is installed within new air handling units during their original equipment manufacturer, preassembling the modular bulkhead wall with the transition frame 31 allows the installer to use a crane to lift and set the modular bulkhead wall within the new air handling unit without damaging the modular bulkhead wall.
Adjacent panels within the modular bulkhead wall are attached to each other by interlocking the stiffening flange 47 of one panel against an interior side of the c-channel 45 of the other panel, as shown in
For example, as shown in
The intermediate bulkhead stiffening element comprises a polygonal tubular profile that provides structural support for the bulkhead wall substantially where the fan panel 15 and filler panel 25 meet. The intermediate bulkhead stiffening element increases the stability of the modular bulkhead wall and as such, is critical to the successful performance of the modular bulkhead wall. The modular bulkhead wall must adequately resist various static and dynamic forces, including differential pressures resulting on the front and back sides of the modular bulkhead wall during the operation of the air handling unit's fan system. While the intermediate bulkhead stiffening elements shown in the Figures as having a substantially quadrilateral cross-sectional profile, it is also anticipated that alternative embodiments of the modular bulkhead system 5 may provide intermediate bulkhead stiffening element(s) of other polygonal cross-sectional profiles.
Although it is anticipated that the modular bulkhead wall does not always require a filler panel 25, its use increases the stability of the modular bulkhead wall because its inclusion provides an additional intermediate bulkhead stiffening element, which increases the stiffness of the modular bulkhead wall.
Once the modular bulkhead wall is installed within the cabinet 80, one or more fans 6 may then be securely attached and hung on the modular bulkhead wall. The bulkhead wall provides support for the suspension of the fans by attachment adjacent to the perimeter of each opening 8. Each fan 6 provides a fan plate 7 that is integrally attached to the fan 6. The fan plate 7 comprises a substantially flat plate that is further comprised by a plurality of sides, of which include a bottom side. The fan plate 7 is configured to support suspension of the fan 6.
Each panel opening 8 provides a ledge 60 below its bottom edge, as shown in
The modular bulkhead system 5 also supports a quick-connect box 65, which is used to power and control the one or more fans 6. The quick-connect box 65 is electronically coupled to each fan 6 using a plurality of fan wires. It is anticipated that a plurality pre-punched holes 40, or indicators for points of attachment, could be provided on the modular bulkhead wall to improve the efficiency of the installation of the fan wires.
While the embodiments of the invention have been disclosed, certain modifications may be made by those skilled in the art to modify the invention without departing from the spirit of the invention.
Claims
1. An HVAC modular bulkhead system for support of one or more suspended fans comprising:
- a modular bulkhead wall;
- wherein the modular bulkhead wall further comprises a plurality of interlocking vertical panels;
- wherein the plurality of interlocking vertical panels are aligned side-by-side substantially perpendicular to the longitudinal direction of an airstream;
- wherein the one or more suspended fans produce the airstream in the longitudinal direction;
- wherein the plurality of interlocking vertical panels further comprise a first side panel, a second side panel, and at least one middle panel;
- wherein the at least one middle panel is configured as a fan panel;
- wherein the fan panel includes at least one panel opening;
- wherein the fan panel is configured to support attachment of one or more of the suspended fans;
- wherein the first side panel provides a frame attachment end and a stiffening flange;
- wherein the second side panel provides a frame attachment end and a c-channel;
- wherein the at least one middle panel provides a stiffening flange and a c-channel;
- wherein the stiffening flange of the first side panel interlocks and attaches with the c-channel of the at least one middle panel;
- wherein the stiffening flange of the at least one middle panel interlocks and attaches with the c-channel of the second side panel;
- wherein a tubular intermediate bulkhead stiffening element is formed by the interlocking and attachment of the stiffening flange and the c-channel of adjacent panels.
2. The modular bulkhead system of claim 1, wherein a structural frame is secured to the first side panel, the at least one middle panel, and the second side panel.
3. The modular bulkhead system of claim 1, wherein a transition frame is secured to the first side panel, the at least one middle panel, and the second side panel.
4. The modular bulkhead system of claim 1, wherein a quick-connect box is attached to the modular bulkhead wall.
5. The modular bulkhead system of claim 1, wherein the c-channel includes a c-channel lip configured as an attachment surface for between adjacent panels.
6. The modular bulkhead system of claim 5, wherein the c-channel lip is disposed within the tubular intermediate bulkhead stiffening element.
7. The modular bulkhead system of claim 5, wherein a front surface of the c-channel lip abuts a back surface of the adjacent panel once the panels are interlocked and attached.
8. The modular bulkhead system of claim 5, wherein each c-channel lip is attached to an adjacent panel by fasteners that are connected through aligned pre-punched holes disposed in the c-channel lip and in the adjacent panel.
9. The modular bulkhead system of claim 1, wherein the at least one middle panel includes at least one filler panel, and wherein each of the stiffening flange and the c-channel of the at least one filler panel interlock and attach with each of the corresponding stiffening flange or c-channel of the adjacent panels.
10. The modular bulkhead system of claim 9, wherein the at least one filler panel is configured to provide a bulkhead door.
11. The modular bulkhead system of claim 1, wherein at least one ledge is provided beneath the at least one panel opening of the fan panel.
12. An HVAC modular bulkhead system for support of one or more suspended fans comprising:
- a modular bulkhead wall; wherein the modular bulkhead wall further comprises a plurality of interlocking vertical panels; wherein the plurality of interlocking vertical panels are aligned side-by-side substantially perpendicular to the longitudinal direction of an airstream; wherein the one or more suspended fans produce the airstream in the longitudinal direction; wherein the plurality of interlocking vertical panels further comprise a first side panel, a second side panel, and at least one middle panel; wherein the at least one middle panel is configured as a fan panel; wherein the fan panel includes at least one panel opening; wherein the fan panel is configured to support attachment of one or more of the suspended fans; wherein the first side panel provides a frame attachment end and a stiffening flange; wherein the second side panel provides a frame attachment end and a c-channel; wherein the at least one middle panel provides a stiffening flange and a c-channel; wherein the stiffening flange of the first side panel interlocks and attaches with the c-channel of the at least one middle panel; wherein the stiffening flange of the at least one middle panel interlocks and attaches with the c-channel of the second side panel; wherein an intermediate bulkhead stiffening element is formed by the interlocking and attachment of the stiffening flange and the c-channel of adjacent panels; and
- one or more fans; wherein the one or more fans each has an integrally attached fan plate; wherein, during suspension of the one or more integrally attached fan and fan plate on the fan panel, the fan plate covers the at least one fan panel opening and is attached thereto and provides support for suspension of the at least one fan from the at least one fan panel.
13. The modular bulkhead system of claim 12, wherein a frame is secured to the first side panel, the at least one middle panel, and the second side panel.
14. The modular bulkhead system of claim 13, wherein the frame is one of either a structural frame or a transition frame.
15. The modular bulkhead system of claim 12, wherein a quick-connect box is attached to the modular bulkhead wall.
16. The modular bulkhead system of claim 12, wherein the c-channel includes a c-channel lip configured as an attachment surface for the adjacent panel.
17. The modular bulkhead system of claim 12, wherein the at least one middle panel includes at least one filler panel, and wherein each of the stiffening flange and the c-channel of the at least one filler panel interlock and attach with each of the corresponding stiffening flange or c-channel of the adjacent panels.
18. The modular bulkhead system of claim 12, wherein at least one ledge is provided beneath the at least one panel opening of the fan panel.
19. A method of installing an HVAC modular bulkhead system for support of one or more suspended fans within an air handling unit cabinet comprising:
- Obtaining the HVAC modular bulkhead system of claim 12;
- Positioning the plurality of interlocking vertical panels to be aligned side-by-side substantially perpendicular to the longitudinal direction of the suspended fan airstream;
- Attaching the frame attachment end of the first side panel to a frame of the cabinet;
- Securing the top and bottom ends of the first side panel to the frame of the cabinet;
- Attaching the c-channel of the at least one middle panel to the stiffening flange of the first side panel;
- Securing the top and bottom ends of the at least one middle panel to the frame of the cabinet;
- Attaching the c-channel of the second side panel to the stiffening flange of the at least one middle panel;
- Attaching the frame attachment end of the second side panel to a frame of the cabinet;
- Securing the top and bottom ends of the second side panel to the frame of the cabinet, thereby forming the modular bulkhead wall;
- Suspending each of the one or more integrally attached fan and fan plate on each of the fan panels such that the fan plate covers the at least one fan panel opening; and
- Attaching each of the fan plates to the fan panels, thereby supporting suspension of each of the at least one fan from the at least one fan panel.
20. The method of installing the HVAC modular bulkhead system of claim 19, further including the step of attaching a quick-connect box to the modular bulkhead wall.
Type: Application
Filed: Jan 29, 2024
Publication Date: May 23, 2024
Inventors: Matthew Wayne Kent (Saint Augustine, FL), Luis Burgos (Jacksonville, FL)
Application Number: 18/426,256