Systems and Methods for Air Handler Systems with a Backwards Curved Centrifugal Fan or Mixed Flow Fan

Abstract

Systems and methods for an air handler system including a backwards curved centrifugal fan or a mixed flow fan with a rear mounted motor are provided. The air handler system may include a housing defining an inlet and an outlet and an airflow channel therebetween. A backwards curved centrifugal fan or a mixed flow fan may be positioned within the airflow channel and a motor may be secured to the backside of the fan such that airflow may be received from the inlet and redirected at least partially perpendicularly such that the airflow moves around the motor of the fan and out the outlet of the air handler. A fan controller and/or a fan enclosure may optionally be positioned on the backside of the fan. The air handler may further include heating systems such as heat exchanger coils and/or an electric heating system with one or more resistive coils and/or a hydronic heating coil.

We claim: 
     
         1 . An air handler system comprising:
 a housing comprising an inlet and an outlet and at least one air channel positioned between the inlet and the outlet, the housing having a longitudinal axis;   a plurality of coils disposed within the housing and configured to receive a first fluid and exchange thermal energy with the first fluid; and   a fan assembly disposed within the housing, the fan assembly comprising:
 a fan comprising a fan housing including a front-side and a backside and fan blades disposed within the fan housing, the fan blades configured to receive an airflow in a first direction and redirect at least a portion of the airflow to a second direction at least partially perpendicular to the first direction; 
 a motor in mechanical communication with the fan blades of the fan and configured to cause the fan blades to rotate with respect to the housing, the motor coupled to the backside of the fan housing; 
 a fan controller configured to control operation of the motor; and 
 a fan enclosure coupled to the backside of the fan and configured to house the motor and the fan controller, 
   wherein the fan assembly together with the at least one air channel is configured to cause the airflow to enter the inlet of the housing, traverse the plurality of coils, transition from the first direction to the second direction, and exit the outlet of the housing, the first direction parallel to the longitudinal axis of the housing.   
     
     
         2 . The air handler system of  claim 1 , further comprising, coupled to the fan enclosure, one or more of an electric heating system or a hydronic heating system configured to transfer thermal energy to the airflow in the housing. 
     
     
         3 . The air handler system of  claim 2 , wherein the fan enclosure comprises one or more of thermal insulation or electric insulation. 
     
     
         4 . The air handler system of  claim 2 , wherein the electric heating system comprises at least one electric resistive heating element having an annular shape. 
     
     
         5 . The air handler system of  claim 2 , wherein the fan enclosure is metallic and a connection between the electric heating system and the fan enclosure is thermally insulated. 
     
     
         6 . The air handler system of  claim 1 , wherein the fan is a backwards curved centrifugal fan. 
     
     
         7 . The air handler system of  claim 1 , wherein the fan is a mixed flow fan. 
     
     
         8 . The air handler system of  claim 1 , further comprising a remote controller configured to cause the fan controller to adjust operation of the motor, wherein the fan controller is in wired communication with the motor. 
     
     
         9 . The air handler system of  claim 1 , further comprising one or more of a second plurality of coils configured to receive the first fluid, a compressor, or an expansion valve. 
     
     
         10 . The air handler system of  claim 1 , further comprising a grommet, a compartment comprising a protection plate, and an airflow shroud connected to the housing and the fan assembly via the compartment, the airflow shroud configured to direct airflow from the fan to the outlet of the housing, wherein the grommet is positioned between the grommet and the compartment. 
     
     
         11 . An air handler system comprising:
 a housing comprising an inlet and an outlet and at least one air channel positioned between the inlet and the outlet;   a plurality of coils disposed within the housing and configured to receive a first fluid and exchange thermal energy with the first fluid;   a fan assembly disposed within the housing, the fan assembly comprising:
 a fan comprising a fan housing including a front-side and a backside and fan blades disposed within the housing, the fan blades configured to receive an airflow in a first direction and redirect at least a portion the airflow to a second direction at least partially perpendicular to the first direction; and 
 a motor in mechanical communication with the fan blades of the fan and configured to cause the fan blades to rotate with respect to the housing, the motor coupled to the backside of the fan housing; and 
   a controller disposed within the housing, the controller in wired or wireless communication with the motor and configured to control operation of the motor;   wherein the fan assembly together with the at least one air channel is configured to cause air to enter the inlet of the housing, traverse the plurality of coils, transition from the first direction parallel to the second direction and exit the outlet of the housing, the first direction parallel to the parallel to the longitudinal axis of the housing.   
     
     
         12 . The air handler system of  claim 11 , wherein the controller is coupled to the backside of the fan housing. 
     
     
         13 . The air handler system of  claim 12 , further comprising a fan enclosure coupled to the backside of the fan and configured to house the motor and the controller. 
     
     
         14 . The air handler system of  claim 13 , wherein the fan enclosure comprises one or more of thermal or electric insulation. 
     
     
         15 . The air handler system of  claim 11 , further comprising an electric heating system configured to transfer thermal energy to the air in the housing and coupled to the backside of the fan. 
     
     
         16 . The air handler system of  claim 15 , wherein the electric heating system comprises at least one electric resistive heating element having an annual shape. 
     
     
         17 . The air handler system of  claim 11 , wherein the fan is a backwards curved centrifugal fan. 
     
     
         18 . The air handler system of  claim 11 , wherein the fan is a mixed flow fan. 
     
     
         19 . The air handler system of  claim 11 , further comprising a remote controller configured to cause the controller to adjust operation of the motor, wherein the controller is in wired communication with the motor. 
     
     
         20 . The air handler system of  claim 11 , further comprising an airflow shroud connected to the housing and the fan assembly and configured to direct airflow from the fan to the outlet of the housing.