FAN ASSEMBLY INCLUDING ACCESS OPENING AND SUPPORT CUSHION

Abstract

A fan assembly is provided. The fan assembly includes a fan wheel including a plurality of blades, a motor configured to rotate the fan wheel, a fan case having a circumferential wall surrounding the fan wheel, an access opening formed in the circumferential wall, and a support cushion. The support cushion is located between the circumferential wall and the fan wheel.

Claims

1. A fan assembly comprising: a fan wheel including a plurality of blades; a motor configured to rotate the fan wheel; a fan case having a circumferential wall surrounding the fan wheel; an access opening formed in the circumferential wall; a support cushion positioned between the circumferential wall and the fan wheel, wherein an edge of the access opening is located on the circumferential wall between 10 and 45 degrees away from a first reference line extending from a center of rotation of the fan wheel toward the circumferential wall; and a point in the support cushion is located between the fan wheel and the circumferential wall between 0 and 10 degrees on either side of the first reference line.

2. The fan assembly of claim 1, wherein the support cushion is located beneath the fan wheel when the fan assembly is in an upright position.

3. The fan assembly of claim 2, wherein the support cushion is located beneath a center of gravity of the fan wheel when the fan assembly is in the upright position.

4. The fan assembly of claim 1, wherein the first reference line is a vertical line when the fan assembly is in an upright position.

5. The fan assembly of claim 1, further comprising an access cover configured to cover the access opening.

6. The fan assembly of claim 1, wherein the support cushion contacts at least one blade of the plurality of blades.

7. The fan assembly of claim 1, wherein a width of the support cushion in a radial direction with respect to the center of rotation of the fan wheel along the first reference line is greater than a distance between the fan wheel and the access opening along a second reference line extending from the center of rotation of the fan wheel and passing through the access opening at any point.

8. The fan assembly of claim 1, wherein the support cushion comprises a wedge and a receiving cushion, and the wedge is located inside the receiving cushion.

9. The fan assembly of claim 8, wherein the receiving cushion is configured such that it can compress to an unassembled width when the wedge is removed from inside the receiving cushion, the unassembled width being smaller than an assembled width when the wedge is inserted inside the receiving cushion.

10. A fan assembly comprising: a fan wheel including a plurality of blades; a motor configured to rotate the fan wheel; a fan case having a circumferential wall surrounding the fan wheel; an access opening formed in the circumferential wall; a support cushion positioned between the circumferential wall and the fan wheel, wherein an edge of the access opening is located on the circumferential wall between 10 and 45 degrees away from a first reference line extending from a center of rotation of the fan wheel toward the circumferential wall; a point in the support cushion is located between the fan wheel and the circumferential wall between 0 and 10 degrees on either side of the first reference line; the support cushion has a first width in a radial direction of the fan wheel; and the support cushion is configured such that it can be compressed to a second width that is smaller than the first width.

11. The fan assembly of claim 10, wherein the first reference line is a vertical line when the fan assembly is in an upright position.

12. The fan assembly of claim 10, wherein the support cushion comprises a wedge and a receiving cushion, and the wedge is located inside the receiving cushion.

13. The fan assembly of claim 12, wherein the receiving cushion is configured such that it can compress to an unassembled width when the wedge is removed from inside the receiving cushion, the unassembled width being smaller than an assembled width when the wedge is inserted inside the receiving cushion.

14. The fan assembly of claim 12, wherein the wedge comprises a head and a handle, the head has a wedge shape that tapers into a thin edge, the handle is attached to the thin edge of the head, the receiving cushion comprises a panel and at least two blocks, each of the at least two blocks has a first end and a second end, the panel is connected to the first end of each of the at least two blocks, the panel comprises a hole, the handle is inserted in the hole, and the support cushion is configured such that when the handle is pulled, the head is configured to be inserted into a slot formed between the at least two blocks such that the second ends of the at least two blocks are pushed apart from each other by the head.

15. The fan assembly of claim 14, wherein when viewed in the radial direction with respect to the center of rotation of the fan wheel, the at least two blocks of the receiving cushion do not overlap with the access opening.

16. A fan assembly comprising: a fan wheel including a plurality of blades; a motor configured to rotate the fan wheel; a fan case having a circumferential wall surrounding the fan wheel; an access opening formed in the circumferential wall; and a support cushion, wherein the support cushion includes a top cushion and a bottom cushion, and the support cushion protrudes through the access opening such that the top cushion is located between the fan wheel and the circumferential wall, and the bottom cushion is located between the circumferential wall and a support surface on which the fan assembly is disposed.

17. The fan assembly of claim 16, wherein the support cushion further comprises a connecting panel, the top cushion is connected to a first side of the connecting panel, and the bottom cushion is connected to the first side of the connecting panel.

18. The fan assembly of claim 16, wherein the circumferential wall is sandwiched between the top cushion and the bottom cushion.

19. The fan assembly of claim 16, wherein the support cushion is one of a plurality of support cushions, and each support cushion of the plurality of support cushions is positioned at an equal distance from a center of gravity of the fan wheel in an axial direction of the fan wheel.

20. The fan assembly of claim 16, wherein a first reference line extending from a center of rotation of the fan wheel toward the circumferential wall passes through the access opening, and the first reference line is a vertical line when the fan assembly is in an upright position.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0059] The accompanying figures, where like reference numerals refer to identical or functionally similar elements and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate an exemplary embodiment and to explain various principles and advantages in accordance with the present disclosure.

[0060] FIG. 1 is a side view of a fan assembly according to disclosed embodiments.

[0061] FIG. 2 is a front view of the fan assembly while an access cover is attached to the fan assembly according to disclosed embodiments.

[0062] FIG. 3 is a front view of the fan assembly when the access cover is removed from the fan assembly according to disclosed embodiments.

[0063] FIG. 4 is a side view of a support cushion in an unexpanded state according to disclosed embodiments.

[0064] FIG. 5 is a side view of the support cushion in an expanded state according to disclosed embodiments.

[0065] FIG. 6 is a top view of the support cushion in the unexpanded state according to disclosed embodiments.

[0066] FIG. 7A is a cross-sectional view taken along the line A-A in FIG. 2 while the access cover is attached to the fan assembly according to disclosed embodiments.

[0067] FIG. 7B is a cross-sectional view taken along the line A-A in FIG. 2 when the access cover is removed from the fan assembly according to disclosed embodiments.

[0068] FIG. 8 is a top view of an access cover having access cover projections according to alternative embodiments.

[0069] FIG. 9 is a side view of an access cover having access cover projections according to alternative embodiments.

[0070] FIG. 10 is a front view of the fan assembly while an access cover is attached to the fan assembly according to alternative embodiments.

[0071] FIG. 11 is a side view of a fan assembly according to alternative embodiments.

[0072] FIG. 12A is a cross-sectional view taken along the line B-B in FIG. 11 according to alternative embodiments.

[0073] FIG. 12B is a cross-sectional view taken along the line B-B in FIG. 11 according to alternative embodiments.

DETAILED DESCRIPTION

[0074] The instant disclosure is provided to further explain in an enabling fashion the best modes of performing one or more embodiments of the present invention. The disclosure is further offered to enhance an understanding and appreciation for the inventive principles and advantages thereof, rather than to limit in any manner the invention. The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued.

[0075] It is further understood that the use of relational terms such as first and second, and the like, if any, are used solely to distinguish one from another entity, item, or action without necessarily requiring or implying any actual such relationship or order between such entities, items or actions. It is noted that some embodiments may include a plurality of processes or steps, which can be performed in any order, unless expressly and necessarily limited to a particular order; i.e., processes or steps that are not so limited may be performed in any order.

[0076] FIG. 1 is a side view of a fan assembly 100 in an upright position. FIG. 2 is a front view of a fan assembly 100 in an upright position while an access cover 140 covers an access opening 130. FIG. 3 is a front view of a fan assembly 100 in an upright position with the access opening 130 uncovered.

[0077] As shown in FIGS. 1-3, the fan assembly 100 includes a fan case 110, an outlet 120, an access opening 130, an access cover 140, a fan wheel 150, a motor 180, a motor shaft 190, and a support cushion 200. The fan assembly 100 is, for example, a centrifugal blower assembly. The fan assembly 100 may be provided, for example, as part of an air handler assembly.

[0078] The fan case 110 has a circumferential wall 112 which surrounds a fan wheel 150. The circumferential wall 112 is substantially spiral-shaped.

[0079] The fan case 110 further includes a plenum 111. The plenum 111 surrounds an inlet of the fan assembly 100 through which air is drawn into the fan case 110. The fan assembly 100 also includes the outlet 120 which discharges air blown out from the fan assembly 100.

[0080] The motor 180 is configured to rotate the fan wheel 150. The motor 180 is connected to the fan wheel 150 via the motor shaft 190. The motor 180 is provided outside of the fan case 110. However, the motor 180 may be positioned inside of the fan case 110.

[0081] The fan wheel 150 comprises a plurality of blades 152. The fan wheel 150 is configured to rotate about a center of rotation 154 of the fan wheel 150 when it is driven by the motor 180. When the fan wheel 150 is rotated, air is drawn into the fan case 110 and is discharged from the outlet 120.

[0082] Furthermore, the fan wheel 150 may include a center plate 153. The center plate 153 is a plate that is located in a central portion of the fan wheel 150 in an axial direction of the fan wheel 150. The center plate 153 may be substantially circular. The center plate 153 may be located in the center of the fan wheel 150 in the axial direction of the fan wheel 150. Alternatively, the center plate 153 may be located within 25% of the axial length of the fan wheel 150 from the center of the fan wheel 150 in the axial direction of the fan wheel 150. The motor shaft 190 may be coupled to the center plate 153 of the fan wheel 150. The blades 152 may protrude further in the radial direction of the fan wheel 150 than the center plate 153 does. However, in some embodiments, the center plate 153 may protrude equally as far or farther than the blades 152 in the radial direction of the fan wheel 150.

[0083] An access opening 130 is formed in the circumferential wall 112 of the fan case 110. The access opening 130 is an opening or hole formed in the circumferential wall 112. The access opening 130 may be substantially rectangular in shape. However, the access opening 130 may also have an elliptical shape, a circular shape, or any other suitable shape.

[0084] The fan assembly 100 may include an access cover 140 that is configured to cover the access opening 130. The access cover 140 may be removably attached to the fan case 110, and particularly may be removably attached to the circumferential wall 112 of the fan case 110.

[0085] For example, the access cover 140 may be removably attached to the circumferential wall 112 of the fan case 110 by at least one fastener 160. The at least one fastener 160 may include at least one of a bolt, a screw, a cotter pin, or a clasp. The at least one fastener 160 is configured to lock the access cover 140 in place to cover the access opening 130 when the access cover 140 is in a closed position. The access cover 140 may be attached to the circumferential wall 112 of the fan case 110 in an air-tight manner when it is in the closed position.

[0086] The access cover 140 may be connected to the circumferential wall 112 of the fan case 110 by at least one hinge 170. Furthermore, at least one fastener 160 may be provided along with the at least one hinge 170 to lock the access cover 140 in place to cover the access opening 130 when the access cover 140 is in a closed position. The access cover 140 may be attached to the circumferential wall 112 of the fan case 110 in an air-tight manner when it is in the closed position. When the at least one fastener 160 is removed or unlatched from the access cover 140, the access cover 140 may swing open on the at least one hinge 170 to uncover the access opening 130.

[0087] The access cover 140 is configured to have a size and shape such that it fully covers the access opening 130 in a closed position in which the access cover 140 is placed over the access opening 130. The access cover 140 may be slightly larger than the access opening 130. The access cover 140 may include a pliable material (not shown) on the surfaces of the access cover 140 that are configured to contact the fan case 110 when the access cover 140 is in the closed position. The access cover 140 is preferably attached to the fan case 110 in an air-tight manner when the access cover 140 is in the closed position.

[0088] In an alternative embodiment, the access cover may include least one access cover projection 142 configured to removably attach the access cover 140 to the fan case 110. FIGS. 8 and 9 illustrate an embodiment of the access cover 140 including access cover projections 142.

[0089] Access cover projections 142 may be provided at opposite edges of the access cover 140. In an exemplary embodiment, two access cover projections 142 are provided. As illustrated in FIG. 10, when the access cover 140 covers the access opening 130, the access cover projections 142 are configured to be inserted into the access opening 130 and contact an inner surface of the circumferential wall 112 of the fan case 110. The sides of the access cover 140 which do not include the access cover projections 142 may extend past the edges of the access opening 130 to overlap the circumferential wall 112 of the fan case 110. In this manner, the access cover 140 is secured to the circumferential wall 112 of the fan case 110 so that the access cover 140 fully covers the access opening 130 in an airtight manner.

[0090] The access cover 140 may be formed of a flexible material. The flexible material may be, e.g., a thin, flexible metal or a flexible plastic. In this case, the access cover 140 may be installed or uninstalled by flexing the access cover 140 to create clearance with the access opening 130. When the access cover 140 is flexed, the at least one access cover projection 142 may be engaged or disengaged from the fan case 110. When the access cover 140 is not actively flexed, its flexible material causes it to spring back into its original shape. Accordingly, the access cover 140 can be removably attached to the circumferential wall 112 of the fan case 110. The access cover 140 may be curved so that the shape of the access cover 140 matches the shape of the circumferential wall 112 of the fan case 110 when the access cover 140 covers the access opening 130.

[0091] FIG. 7A is a cross-sectional view illustrating a support cushion 200 positioned inside of the fan case 110 when the access cover 140 is covering the access opening 130. FIG. 7B is a cross-sectional view illustrating a support cushion 200 positioned inside of the fan case 110 when the access opening 130 is not covered by the access cover 140.

[0092] As shown in FIGS. 7A and 7B, support cushion 200 is placed between the fan wheel 150 and the fan case 110 when the fan assembly 100 is in a packaged configuration for shipping. The support cushion 200 preferably contacts the fan wheel 150 and the circumferential wall 112 of the fan case 110 when it is installed within the fan case 110.

[0093] The support cushion 200 is configured to prevent damage to the fan wheel 150 during shipping of the fan assembly 100. The fan assembly 100 may be shipped by itself, or may be shipped as a part of, e.g., an air handler unit. During transit of the fan assembly 100, the fan assembly 100 may be subjected to impacts from dropping of the fan assembly 100 or jostling of the fan assembly 100. Therefore, components of the fan assembly 100 that are prone to bending or other damage must be protected during shipping.

[0094] When the support cushion 200 is installed in the fan case 110 prior to the shipping of the fan assembly 100, the support cushion 200 supports the fan wheel 150 and arrests motion of the fan wheel 150 if an impact is applied to the fan assembly 100 during shipping.

[0095] The support cushion 200 preferably applies a support force that is centered at a center of the fan wheel 150 in an axial direction of the fan wheel 150. In particular, the support cushion 200 may be located below a center of gravity 151 of the fan wheel 150 when the fan assembly 100 is in an upright position. The center of gravity 151 of the fan wheel 150 may be located at the center plate 153 in an axial direction of the fan wheel 150.

[0096] The support cushion 200 is preferably located below a bottom of the fan wheel 150 when the fan assembly 100 is in an upright position. The support cushion 200 may be positioned below the center plate 153 of the fan wheel 150 when the fan assembly 100 is in an upright position.

[0097] The support cushion 200 contacts one or more of the blades 152 of the fan wheel 150. The support cushion 200 may be configured to apply an upward force to the fan wheel 150 while it is installed in the fan case 110. The upward force may be centered around the center plate 153 of the fan wheel 150 so as to be evenly distributed in the axial direction of the fan wheel 150.

[0098] Support forces provided by the support cushion 200 to the fan wheel 150 are preferably balanced in the axial direction of the fan wheel 150. Creation of bending forces may thus be prevented, and warping of the center plate 153 that causes unbalance and vibration of the fan wheel 150 may be avoided. Therefore, the likelihood that parts of the fan assembly 100 will need to be repaired or replaced due to damage in transit is reduced. Accordingly, the manufacturer and/or the customer do not have to spend time and money repairing the fan assembly 100.

[0099] In an embodiment in which the center plate 153 of the fan wheel 150 protrudes at least as far in the radial direction of the fan wheel 150 as the blades 152, the center plate 153 may contact the support cushion 200. The support cushion 200 may additionally contact at least one of the blades 152 of the fan wheel 150.

[0100] The support cushion 200 may be a single component formed of, e.g., cardboard, polymeric foam, spring metal, rubber, plastic, or silicone. The support cushion 200 may be flexible or may be substantially rigid.

[0101] The support cushion 200 may be formed of two or more components. The components may be placed on each side of the center plate 153 of the fan wheel 150 in an axial direction of the fan wheel 150. For example, two components forming the support cushion 200 may each be placed at a substantially equal distance from the center plate 153 in an axial direction of the fan wheel 150 on opposite sides of the center plate 153. The two components of the support cushion 200 may be separated from each other in an axial direction of the fan wheel 150.

[0102] The support cushion 200 has a width in the radial direction of the fan wheel 150 such that it contacts the fan wheel 150 and the circumferential wall 112 of the fan case 110 when it is installed within the fan case 110. In other words, the support cushion 200 has a shape and size substantially corresponding to a gap between the fan wheel 150 and the circumferential wall 112 of the fan case 110.

[0103] The support cushion 200 may be configured such that it has a first width W1 in a radial direction of the fan wheel 150 when it is located between the fan wheel 150 and the circumferential wall 112 of the fan case 110. The first width W1 of the support cushion 200 preferably corresponds to a distance between the fan wheel 150 and the circumferential wall 112 at the location at which the support cushion 200 is placed. The support cushion 200 may be capable of being compressed to have a second width W2 that is smaller than the first width W1.

[0104] The access opening 130 is positioned on the circumferential wall 112 of the fan case 110 such that the support cushion 200 can be positioned inside of the fan case 110 via the access opening 130.

[0105] A first reference line R1 extends from a center of rotation 154 of the fan wheel 150 toward the circumferential wall 112 of the fan case 110. The first reference line R1 may be located in a plane that is perpendicular to an axis of rotation of the fan wheel 150. The first reference line R1 may be a vertical line when the fan assembly 100 is in an upright position. Furthermore, the first reference line R1 may pass through a center of gravity 151 of the fan wheel 150.

[0106] An edge 132 of the access opening 130 is located on the circumferential wall 112 of the fan case 110 between 10 degrees and 45 degrees from the first reference line R1 on either side of the first reference line R1 in a circumferential direction of the fan wheel 150. The edge 132 of the access opening 130 may particularly be between 15 and 30 degrees away from the first reference line R1. The edge 132 of the access opening 130 may be an edge of the access opening 130 that is closest to the first reference line R1.

[0107] The access opening 130 may be located on a side of the fan case 110 that is furthest from the outlet 120. In particular, the access opening 130 may be located on the circumferential wall 112 of the fan case 110 between 10 degrees and 45 degrees from the first reference line R1 on a side of the first reference line R1 that is further from the outlet 120 in a circumferential direction of the fan wheel 150.

[0108] However, the access opening 130 may be located on the circumferential wall 112 of the fan case 110 directly below the support cushion 200. In this case, an edge 132 of the access opening 130 may be located between 0 and 15 degrees on either side of the first reference line R1.

[0109] The edge 132 of the access opening may be located between 0 degrees and 45 degrees from the first reference line R1 on a side of the first reference line R1 that is further from the outlet 120 in a circumferential direction of the fan wheel 150 or between 0 and 10 degrees from the first reference line R1 on a side of the first reference line R1 that is closer to the outlet 120 in a circumferential direction of the fan wheel 150.

[0110] A point in the support cushion 200 is located between the fan wheel 150 and the circumferential wall 112 of the fan case between 0 and 10 degrees on either side of the first reference line R1 in a circumferential direction of the fan wheel 150. The point in the support cushion 200 may be a point which contacts the fan wheel 150. The point in the support cushion 200 may be a point which is directly below the center of gravity 151 of the fan wheel 150 when the fan assembly 100 is in an upright position. The point in the support cushion 200 may be a point which is directly below the center plate 153 of the fan wheel 150 when the fan assembly 100 is in an upright position.

[0111] A width of the support cushion 200 in a radial direction with respect to the center of rotation 154 of the fan wheel 150 along the first reference line R1 is greater than a distance between the fan wheel 150 and the access opening 130 along a second reference line R2 extending from the center of rotation 154 of the fan wheel 150 and passing through the access opening 130 at any point. The second reference line R2 may pass through the center of the access opening 130. Alternatively, the second reference line R2 may pass through the edge 132 of the access opening 130 that is closest to the first reference line R1.

[0112] In other words, the distance between the fan wheel 150 and the access opening 130 in a radial direction of the fan wheel 150 may be smaller than a first width W1 of the support cushion 200. Due to a shape of the circumferential wall 112, the distance between the circumferential wall 112 and the fan wheel 150 near a bottom of the circumferential wall 112 where the support cushion 200 is located is larger than a distance between the portion of the circumferential wall 112 at which the access opening 130 is formed and the fan wheel 150. As such, the support cushion 200 may be configured such that it can be compressed to have a second width W2 that is smaller than the first width W1. The second width W2 of the support cushion 200 is equal to or smaller than the distance between the fan wheel 150 and the portion of the circumferential wall 112 at which the access opening 130 is formed along the reference line R2.

[0113] FIG. 4 is a side view of an embodiment of a support cushion 200 in an unexpanded state. FIG. 5 is a side view of the embodiment of the support cushion 200 in an expanded state. FIG. 6 is a top view of the embodiment of the support cushion 200 in the unexpanded state.

[0114] As illustrated in FIGS. 4-6, the support cushion 200 may comprise a wedge 210 and a receiving cushion 220. When the fan assembly 100 is in the packaged configuration, the wedge 210 is inserted inside of the receiving cushion 220 as illustrated in FIG. 5. The receiving cushion 220 is configured such that it can compress to an unassembled width when the wedge 210 is removed from the receiving cushion 220. The unassembled width of the receiving cushion 220 is smaller than an assembled width of the receiving cushion 220 in which the wedge 210 is positioned inside of the receiving cushion 220.

[0115] The wedge 210 may comprise a head 211 and a handle 212. The head 211 of the wedge 210 has a wedge shape that tapers into a thin edge. The handle 212 is attached to the thin edge of the head 211.

[0116] The receiving cushion 220 may comprise at least two blocks 221, a panel 224, a hole 225, and a protrusion 226.

[0117] Each of the at least two blocks 221 has a first end 222 and a second end 223 opposite to the first end 222. Each of the at least two blocks 221 may have a rectangular prism shape. However, the shapes of the at least two blocks 221 are not particularly limited.

[0118] The panel 224 has a first side 227 and a second side 228 opposite to the first side 227. The first side 227 of the panel 224 is connected to the first end 222 of each of the at least two blocks 221. The panel 224 comprises a hole 225 configured to pass from the first side 227 of the panel 224 to the second side 228 of the panel 224. The hole 225 may be positioned between two blocks 221. The receiving cushion 220 may also include a protrusion 226 that protrudes from the second side 228 of the panel 224. However, the receiving cushion 220 may be formed without the protrusion 226.

[0119] When the wedge 210 is not inserted into the receiving cushion 220, the support cushion 200 has a second width W2 that is smaller than the first width W1 of the support cushion 200. To expand the support cushion 200 from the second width W2 to the larger first width W1, the wedge 210 is inserted into the receiving cushion 220. In particular, the handle 212 is inserted into the hole 225 in the panel 224. When the handle 212 is pulled, the head 210 is inserted into a slot formed between the at least two blocks 221. While the head 210 slides into the slot, the head 210 pushes the second ends 223 of the at least two blocks 221 apart from each other. Accordingly, the receiving cushion 220 is expanded from its unassembled width to its larger assembled width. Thus, the support cushion 200 is expanded from the second width W2 to the first width W1. The expansion of the support cushion 200 is stopped when the receiving cushion 220 contacts both the circumferential wall 112 of the fan case 110 and the fan wheel 150.

[0120] At least a portion of the support cushion 200 is formed of cardboard, polymeric foam, metal, wood, or plastic. The head 210 may be formed of a rigid material such as a rigid plastic, a metal, a wood, or another suitable material. The receiving cushion 220 may be formed of a compressible or flexible material such as a polymeric foam, a flexible plastic, or a cardboard. The head 210 may be hollow. Each of the at least two blocks 221 may be hollow.

[0121] When the support cushion 200 is positioned in the fan case 110, the at least two blocks 221 of the receiving cushion 220 preferably do not overlap with the access opening 130 when viewed in the radial direction of the fan wheel 150. However, the handle 212 and the protrusion 226 may be configured to overlap with the access opening 130 when viewed in the radial direction of the fan wheel 150. The protrusion 226 may be configured to contact the access cover 140 when the support cushion 200 is positioned in the fan case 110. Due to this configuration, it is possible for a technician to easily grasp the handle 212 and/or the protrusion 226 of the support cushion 200 by reaching their hand through the access opening 130. Thus, the support cushion 200 can be easily removed from the fan case 110.

[0122] The support cushion 200 is configured to be inserted into the fan case 110 via the access opening 130. The support cushion 200 is placed in the fan case 110 before the fan assembly 100 is shipped or transported. The support cushion 200 must be removed prior to the operation of the fan assembly 100 to prevent damage to the fan wheel 150. When the fan assembly 100 is prepared for shipment, a technician opens and/or removes the access cover 140 to uncover the access opening 130. The technician then inserts the support cushion 200 into the fan case 110.

[0123] The access opening 130 preferably has a size such that a technician may insert their arm into the access opening 130 to reach the inside of the fan case 110. Furthermore, the access opening 130 is larger than the second width W2 of the support cushion 200. In particular, the access opening 130 may be at least three inches wide by three inches tall, and more specifically may be at least four inches wide by five inches tall.

[0124] The technician may insert the wedge 210 and the receiving cushion 220 of the support cushion 200 into the fan case 110 in an unassembled state in which the head 211 of the wedge 210 is not inserted into the receiving cushion 220. Subsequently, the technician may reach into the fan case 110 to pull the handle 212 of the wedge 210 and thus cause the head 211 of the wedge 210 to be inserted between the blocks 221 of the receiving cushion 220. Accordingly, the support cushion 200 expands to have the first width W1 in the radial direction of the fan wheel 150. In the expanded state, the support cushion 200 contacts the fan wheel 150 and the circumferential wall 112 of the fan case 110. In particular, the receiving cushion 220 of the support cushion 200 contacts the fan wheel 150 and the circumferential wall 112 of the fan case 110.

[0125] After the technician has expanded and positioned the support cushion 200 inside the fan case 110, he or she may place the access cover 140 over the access opening 130 and lock the access cover 140 in the closed position using, e.g., the at least one fastener 160. The technician may, for example, place a sticker on the access cover 140 to signal that the support cushion 200 is inside the fan case 110. This reminds the recipient of the fan assembly 100 to remove the support cushion 200 from the fan case 110 before operating the fan assembly 100.

[0126] Alternatively, the access cover 140 may be maintained in a position in which it does not cover the access opening 130 during the shipping of the fan assembly 100. In particular, the access cover 140 may be detached from the fan assembly 100 during shipping. If the access cover 140 is attached to the fan case 110 by the hinge 170, the access cover 140 may be left in an open position in which it is not locked in a closed position by a fastener 160. In this case, as illustrated in FIG. 7B, the handle 212 may protrude from the access opening 130 during shipping. Thus, the recipient of the fan assembly 100 can recognize that the support cushion 200 is inside of the fan case 110 and remove the support cushion 200 prior to starting operation of the fan assembly 100. During shipping, the fan wheel 150 may be prevented from turning by the use of, e.g., a twist tie or a zip tie (not shown).

[0127] When the fan assembly 100 is received at the location at which it is to be installed, a technician may remove the support cushion 200 from the fan case 110 via the access opening 130. The technician may remove the access cover 140 from the fan case 110 by, for example, removing or unlatching the at least one fastener 160. The technician may then reach through the access opening 130 into the fan case 110. The technician may push on the handle 212 to remove the wedge 210 from inside the receiving cushion 220 and accordingly collapse the support cushion 200 to its smaller second width W2. After the support cushion 200 is collapsed, the technician may grasp the protrusion 226 and remove the support cushion 200 from the fan case 110 via the access opening 130.

ALTERNATE EMBODIMENT

[0128] FIG. 11 is a side view of a fan assembly 300. The embodiment of FIG. 11 is similar to the embodiment of FIG. 1, except that one or more support cushions 400 protrude from the fan case 110 through the access opening 130 and contact the fan case 110, the fan wheel 150 and a support surface 500 in the embodiment of FIG. 11. The following discussion will omit descriptions of portions of this embodiment that directly correspond to those of FIG. 1 for ease of disclosure.

[0129] In the fan assembly 300, the access opening 130 is provided below the center of rotation 154 of the fan wheel 150. The first reference line R1 extends from a center of rotation 154 of the fan wheel 150 toward the circumferential wall 112 of the fan case 110. The first reference line R1 may be located in a plane that is perpendicular to an axis of rotation of the fan wheel 150. The first reference line R1 is a vertical line when the fan assembly 300 is in an upright position. In particular, the first reference line R1 may pass through a center of the access opening 130 in the fan assembly 300.

[0130] At least one support cushion 400 is provided to the fan assembly 300. The support cushion 400 includes a top cushion 410, a bottom cushion 420, and a connecting panel 430.

[0131] FIGS. 12A and 12B are cross-sectional views showing the positioning of one or more support cushions 400 with respect to the fan assembly 300.

[0132] As illustrated in FIGS. 12A and 12B, the top cushion 410 of each support cushion 400 contacts the fan wheel 150 and the circumferential wall 112 of the fan case 110 when the fan assembly 300 is in the packaged configuration. In particular, the top cushion 410 contacts at least one blade 152 of the fan wheel 150. The bottom cushion 420 of each support cushion 400 contacts the circumferential wall 112 of the fan case 110 and the support surface 500 when the fan assembly 300 is in the packaged configuration. As such, the circumferential wall 112 of the fan case 110 is sandwiched between the top cushion 410 and the bottom cushion 420 of each support cushion 400 when the fan assembly 300 is in the packaged configuration.

[0133] In the support cushion 400, the top cushion 410 is connected to the bottom cushion 420. In particular, the connecting panel 430 connects the top cushion 410 to the bottom cushion 420. A first end 411 of the top cushion 410 is connected to a first side 431 of the connecting panel 430. A second end 412 of the top cushion 410 is located opposite the first end 411. A first end 421 of the bottom cushion 420 is connected to the first side 431 of the connecting panel 430. A second end 422 of the bottom cushion 420 is located opposite the first end 421.

[0134] As such, the support cushion 400 is configured to wrap around an edge of the access opening 130 such that the support cushion 400 protrudes from the inside of the fan case 110 to the outside of the fan case 110 through the access opening 130. When the fan assembly 300 is in the packaged configuration, most or all of the top cushion 410 is located inside of the fan case 110, and most or all of the bottom cushion 420 is located outside of the fan case 110. In particular, the second end 412 of the top cushion 410 is located inside the fan case 110, and the second end 422 of the bottom cushion 420 is located outside the fan case 110.

[0135] The support surface 500 is a surface that supports the fan assembly 300 during shipping. The support surface 500 may be, for example, a shipping pallet. Alternatively, if the fan assembly 300 is located in an upper portion of another assembly, e.g., an air handler assembly, the support surface 500 may be a ledge or platform provided in the casing of the larger assembly.

[0136] The support cushion 400 may be formed of at least one of cardboard, polymeric foam, spring metal, rubber, plastic, or silicone.

[0137] In the fan assembly 300, the access opening 130 and the at least one support cushion 400 are positioned such that the force applied to the fan wheel 150 by the at least one support cushion 400 is balanced in an axial direction of the fan wheel 150. In particular, if two support cushions 400 are used, each of the two support cushions 400 may be positioned at an equal distance from the center plate 153 of the fan wheel 150 in an axial direction of the fan wheel 150. If a center of gravity 151 of the fan wheel 150 is not positioned at the center plate 153 of the fan wheel 150, each of the two support cushions 400 may be positioned at an equal distance from the center of gravity 151 of the fan wheel 150 in an axial direction of the fan wheel 150. The two support cushions 400 may be placed on opposite sides of the center of gravity 151 of the fan wheel 150 so that the forces applied to the fan wheel 150 from the support cushions 400 are balanced in an axial direction of the fan wheel 150.

[0138] The fan assembly 300 may comprise a plurality of support cushions 400. Each support cushion 400 of the plurality of support cushions 400 may be positioned at an equal distance from the center plate 153 of the fan wheel 150 in an axial direction of the fan wheel 150. Alternatively, each support cushion 400 of the plurality of support cushions 400 may be positioned at an equal distance from the center of gravity 151 of the fan wheel 150 in an axial direction of the fan wheel 150. In particular, the fan assembly 300 may include an even number of support cushions 400, and an equal number of support cushions 400 may be provided on each side of the center of gravity 151 of the fan wheel 150 in the axial direction of the fan wheel. In this manner, the support forces provided by the support cushions 400 are balanced in the axial direction of the fan wheel 150.

[0139] If a single support cushion 400 is provided, as illustrated in FIG. 12B, the access opening 130 and the support cushion 400 may be positioned such that the support cushion 400 is located directly below the center of gravity 151 of the fan wheel 150 when the fan assembly 300 is in an upright position. The support cushion 400 may be located directly below a center plate 153 of the fan wheel 150 when the fan assembly 300 is in an upright position. The support cushion 400 may contact the center plate 153 of the fan wheel 150.

[0140] To position the support cushion 400, a technician may insert the top cushion 410 of the support cushion 400 into the fan case 110 through the access opening 130. In particular, the second end 412 of the top cushion 410 is inserted into the fan case 110 first. The bottom cushion 420 of the support cushion 400 remains outside of the fan case 110. In this manner, the circumferential wall 112 of the fan case 110 is sandwiched between the top cushion 410 and the bottom cushion 420. After one or more support cushions 400 are positioned, the fan assembly 300 is set on the support surface 500 such that the one or more bottom cushions 420 of the one or more support cushions 400 are positioned between the support surface 500 and the fan case 110.

[0141] To remove the one or more support cushions 400 from the fan case 110, the fan assembly 300 is lifted off of the support surface 500, and a technician may simply grasp the bottom cushion 420 of each support cushion 400 and pull the top cushion 410 out of the fan case 110.

[0142] This disclosure is intended to explain how to fashion and use various embodiments in accordance with the invention rather than to limit the true, intended, and fair scope and spirit thereof. The foregoing description is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications or variations are possible in light of the above teachings. The embodiment(s) was chosen and described to provide the best illustration of the principles of the invention and its practical application, and to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims, as may be amended during the pendency of this application for patent, and all equivalents thereof, when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled. The various circuits described above can be implemented in discrete circuits or integrated circuits, as desired by implementation.