CROSS-REFERENCE TO RELAED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63/277,635, filed on 10 November 2021, the entire contents of which are incorporated herein by reference.

FIELD OF THE DISCLOSURE

[0002] The present invention relates generally to air handlers, and more particularly, to an angled fan deck within an air handler for directing a flow of conditioned air to an interior space.

BACKGROUND

[0003] The indoor units of a heating, ventilation, and air conditioning (HVAC) system, commonly referred to as air handlers or fan coils (referred to herein as “air handler(s)”), can assist in circulating air within an interior area of a home or commercial building and facilitate controlling the temperature of air within such interior area. FIG. 1 illustrates a conventional air handling system 100. The air handling system 100 can include an air handler 102, a return duct 104, and a supply duct 106. The main components of the air handler 102 can include a filter 108, a heat exchanger 110, and a fan 112. In particular, conventional air handlers can include a forward curved centrifugal fan, as such fans are relatively inexpensive as compared to other types of fans (e.g., axial fans). The return duct 104 can draw air from an interior area of a home or commercial building and across the filter 108 and the heat exchanger 110. The heat exchanger 110 can include coils configured to receive liquid refrigerant or vapor refrigerant depending on whether the air handler 102 is operating in an air-cooling mode or air-heating mode. As such, the heat exchanger 110 can condition (e.g., heat or cool) the flow of air as the flow of air is directed through the air handler 102. The fan 112 can direct the conditioned air to the interior area via the supply duct 106, thereby providing either an air-cooling effect or air-heating effect. Although the heat exchanger 110 is illustrated as an “A” coil in FIG. 1, the heat exchanger 110 can alternatively be a “Z” or “N” coil or a “V” coil. [0004] The air handler 102 can include a deck 114 configured to support the fan 112. The deck 114 can be positioned horizontally when the air handler 102 is positioned in a vertical configuration, as illustrated in FIG. 1. Alternatively, the deck 114 can be positioned vertically if the air handler 102 is positioned in a horizontal configuration. The deck 114 can be at least partially open such that the fan 112 can draw the flow of conditioned air into an inlet of the fan 112. The outlet of the fan 112 can be substantially aligned with an inlet of the supply duct 106 such that the flow of conditioned air can be directed into the supply duct 106, and thereby into the interior area. Such positioning of the deck 114 is commonly touted as providing easy installation and simple configuration, which can reduce labor costs.

[0005] However, the implementation of new regulations and a widespread focus towards decarbonization have created pressures within the HVAC industry to develop methods and components and/or refine traditional components of HVAC systems to decrease carbon emissions. Accordingly, previous configurations of the components of the HVAC system, including the positioning of the deck within the air handler and/or the use of a forward curved centrifugal fan within the air handler, may become obsolete and/or noncompliant if modifications and/or innovations are not made that would render the air handler in compliance with new regulations.

SUMMARY

[0006] These and other problems can be addressed by the technologies described herein. Examples of the present disclosure relate generally to an air handler including a deck configured to support a fan, with the deck being positioned within the air handler at a nonzero angle. In particular, the angled deck can allow for the air handler to include an axial fan (e.g., a backward curved fan or vane axial fan). Such axial fan can provide various advantages in comparison to the forward curved centrifugal fans used in traditional air handlers including, superior aerodynamic qualities, high static efficiency levels due to the perpendicular nature of expelled air, and low noise. Accordingly, an air handler including an angled deck can facilitate achieving decarbonization efforts and compliance with new energy emission regulations.

[0007] The disclosed technology can include an air handler including a housing having a first end, a second end, and a plurality of side walls defining a cavity or internal volume, a heat exchanger positioned within the cavity and configured to condition a flow of air, a fan deck positioned within the cavity at an angle that is non-zero with respect to horizontal and substantially dividing the cavity into a first section and a second section, and a fan in fluid communication with an aperture of the fan deck. The fan can include an inlet configured to receive a flow of conditioned air from the first section of the cavity.

[0008] The first end of the housing can be configured to be in fluid communication with a return duct, and the second end of the housing can be configured to be in fluid communication with a supply duct. The return duct can be configured to receive the flow of air from an interior area, and the supply duct can be configured to supply the flow of conditioned air.

[0009] An aperture of the second end of the air handler can be in fluid communication with an inlet of the supply duct. The aperture can have a cross-sectional area of greater than half of a cross-sectional area of the second end of the air handler.

[0010] An aperture of the second end of the air handler can be in fluid communication with an inlet of the supply duct. The aperture can have an area that is approximately equal to an area of the second end of the air handler.

[0011] The fan can be one of: a backward curved fan and a vane axial fan.

[0012] The flow of conditioned air can be expelled from at least one of the backward curved fan and the vane axial fan at an angle substantially the same as the angle of the fan deck.

[0013] The angle of the fan deck can be between approximately 5 degrees and approximately 50 degrees, with respect to horizontal.

[0014] The fan can be positioned toward a lower end of the fan deck.

[0015] A diameter of the fan can be between approximately 70% and approximately 90% of a width of the housing of the air handler.

[0016] The first end of the housing can be a bottom end and the second end of the housing can be a top end. In such configuration, the flow of conditioned air can be directed upward through the air handler.

[0017] The first end of the housing can be a top end and the second end of the housing can be a bottom end. In such configuration, the flow of conditioned air can be directed downward through the air handler.

[0018] The fan can be substantially enclosed in a fan housing.

[0019] The disclosed technology can further include an air handling system including an air handler, a return duct, and a supply duct. The air handler can include a housing having a first end, a second end, and a plurality of side walls defining a cavity or internal volume, a heat exchanger positioned within the cavity and configured to condition a flow of air, a fan deck positioned within the cavity at an angle that is non-zero with respect to horizontal and substantially dividing the cavity into a first section and a second section, and an axial fan in fluid communication with an aperture of the fan deck. The axial fan can include an inlet configured to receive a flow of conditioned air from the first section of the cavity. The return duct can be in fluid communication with the first end of the housing of the air handler and can be configured to receive the flow of air from an interior area. The supply duct can be in fluid communication with the second end of the housing of the air handler and can be configured to supply the flow of conditioned air into the interior area.

[0020] The angle can be between approximately 5 degrees and approximately 50 degrees, with respect to horizontal.

[0021] The axial fan can be one of: a backward curved fan and a vane axial fan.

[0022] The disclosed technology can further include a method of manufacturing an air handling system including providing a housing including a first end, a second end, and a plurality of side walls defining a cavity or internal volume, positioning a heat exchanger within the cavity of the housing, positioning a fan deck including at least one aperture at an angle within the cavity of the housing such that the fan deck is at a non-zero angle with respect to horizontal, the fan deck substantially dividing the cavity into a first section and a second section, and affixing a fan to the fan deck, an inlet of the fan being in fluid communication with the first section of the cavity.

[0023] The method can further include affixing a return duct to the first end of the housing and affixing a supply duct to the second end of the housing.

[0024] The fan can be an axial fan and such axial fan can have a diameter that is between approximately 70% and approximately 90% of a width of the housing of the air handling system.

[0025] The fan can be one of: a backward curved fan and a vane axial fan.

[0026] Positioning the fan deck at the angle within the cavity of the housing can include positioning the fan deck at an angle of between approximately 5 degrees and approximately 50 degrees, with respect to horizontal.

[0027] These and other aspects of the present disclosure are described in the Detailed Description below and the accompanying figures. Other aspects and features of the present disclosure will become apparent to those of ordinary skill in the art upon reviewing the following description of specific examples of the present disclosure in concert with the figures. While features of the present disclosure may be discussed relative to certain examples and figures, all examples of the present disclosure can include one or more of the features discussed herein. Further, while one or more examples may be discussed as having certain advantageous features, one or more of such features may also be used with the various other examples of the disclosure discussed herein. In similar fashion, while examples may be discussed below as devices, systems, or methods, it is to be understood that such examples can be implemented in various devices, systems, and methods of the present disclosure.

BRIEF DESCRIPTION OF THE FIGURES

[0028] Reference will now be made to the accompanying figures, which are not necessarily drawn to scale, and wherein:

[0029] FIG. 1 illustrates a schematic diagram of an air handling system, in accordance with prior art.

[0030] FIG. 2A illustrates a schematic diagram of an example air handling system, in accordance with the disclosed technology.

[0031] FIG. 2B illustrates a perspective view of an interior of the example air handler shown in FIG. 2 A, in accordance with the disclosed technology.

[0032] FIG. 3 illustrates a schematic diagram of a flow of air within an example air handler, in accordance with the disclosed technology.

[0033] FIG. 4A illustrates a schematic diagram of an example air handling system in an alternative configuration, in accordance with the disclosed technology.

[0034] FIG. 4B illustrates a perspective view of an interior of the example air handler in the alternative configuration shown in FIG. 4A, in accordance with the disclosed technology.

[0035] FIG. 5 illustrates a flow diagram outlining a method of manufacturing an example air handler, in accordance with the disclosed technology.

DETAILED DESCRIPTION

[0036] The disclosed technology includes an air handling system including an air handler or fan coil (referred to herein as an “air handler”). Air handlers are commonly used in HVAC systems to facilitate circulation of air within an interior area of a home or building and to control the temperature of interior air. The air handler can include a heat exchanger and a fan. A fan deck can be positioned within the air handler such that the interior of the air handler is divided into a first section that includes at least the heat exchanger and a second section that includes at least the fan. The fan deck can be positioned at a non-zero angle with respect to horizontal within the air handler. In particular, the fan deck can be positioned at an angle of between approximately 5 degrees and approximately 50 degrees, with respect to horizontal. By angling the fan deck, an axial fan (e.g., a backward curved fan or vane axial fan) can be used in the air handler as compared to forward curved centrifugal fans. For example, if an axial fan is used in connection with a horizontal fan deck, as in a conventional air handler (e.g., air handler 102 in FIG. 1), the air being expelled from the fan may be directed substantially toward the side walls of the air handler, thereby providing inefficient air flow. However, by angling the fan deck, air can be expelled from the axial fan air at substantially the same angle as the fan deck, thereby providing an efficient upward flow of air that can exit the air handler and be redistributed into interior areas of a home or building. By including an axial fan within an air handler, the air handler can achieve compliance with new energy emission standards and regulations.

[0037] The disclosed technology will be described more fully hereinafter with reference to the accompanying drawings. This disclosed technology can, however, be embodied in many different forms and should not be construed as limited to the examples set forth herein. The components described hereinafter as making up various elements of the disclosed technology are intended to be illustrative and not restrictive. Such other components not described herein may include, but are not limited to, for example, components developed after development of the disclosed technology.

[0038] In the following description, numerous specific details are set forth. But it is to be understood that examples of the disclosed technology can be practiced without these specific details. In other instances, well-known methods, structures, and techniques have not been shown in detail in order not to obscure an understanding of this description. References to “one embodiment,” “an embodiment,” “example embodiment,” “some embodiments,” “certain embodiments,” “various embodiments,” “one example,’ “an example,” “some examples,” “certain examples,” “various examples,” etc., indicate that the embodiment(s) and/or example(s) of the disclosed technology so described may include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase “in one embodiment” or the like does not necessarily refer to the same embodiment, example, or implementation, although it may.

[0039] Throughout the specification and the claims, the following terms take at least the meanings explicitly associated herein, unless the context clearly dictates otherwise. The term “or” is intended to mean an inclusive “or.” Further, the terms “a,” “an,” and “the” are intended to mean one or more unless specified otherwise or clear from the context to be directed to a singular form.

[0040] Unless otherwise specified, the use of the ordinal adjectives “first,” “second,” “third,” etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described should be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

[0041] Unless otherwise specified, all ranges disclosed herein are inclusive of stated end points, as well as all intermediate values. By way of example, a range described as being “from approximately 2 to approximately 4” includes the values 2 and 4 and all intermediate values within the range. Likewise, the expression that a property “can be in a range from approximately 2 to approximately 4” (or “can be in a range from 2 to 4”) means that the property can be approximately 2, can be approximately 4, or can be any value therebetween. Further, the expression that a property “can be between approximately 2 and approximately 4” is also inclusive of the endpoints, meaning that the property can be approximately 2, can be approximately 4, or can be any value therebetween.

[0042] Referring now to the figures, FIG. 2A illustrates an example air handling system 200. The air handling system 200 can include an air handler 202, as further illustrated in FIG. 2B, a return duct 204, and a supply duct 206. The air handler 202, the return duct 204, and the supply duct 206 can all be in fluid communication with each other such that a flow of air can be directed from the return duct 204 through the air hander 202 and out the supply duct 206, as illustrated by the three arrows and as further discussed herein. The air handler 202 can include a housing 208 having a first end 210, a second end 212, and a plurality of side walls 214 defining a cavity 216. As illustrated in FIGs. 2A and 2B, the first end 210 can be a bottom end of the air handler 202 and can be in fluid communication with the return duct 204. The return duct 204 can receive air from an interior area of a house or commercial building that is to be conditioned (e.g., cooled or heated) via the air handler 202. The second end 212 can be a top end of the air handler 202 and can be in fluid communication with the supply duct 206. The supply duct 206 can direct the conditioned air into the interior area. As indicated by the arrows, air from the return duct 204 can be directed across a filter 226 and a heat exchanger 218. The filter 226 can remove undesired contaminants (e.g., dust, dirt, and the like) from the air. The heat exchanger 218 can include a plurality of coils configured to receive liquid refrigerant and vapor refrigerant depending on whether the air handler 202 is operating in an air-heating mode or air-cooling mode. When operating in an air-heating mode, the heat exchanger 218 can receive vapor refrigerant from an outdoor unit (e.g., a condenser of a heat pump system). Air from the return duct 204 can be directed across the heat exchanger 218 and can absorb heat from the vapor refrigerant, thereby heating the air. Alternatively, when operating in an air-cooling mode, the heat exchanger 218 can receive liquid refrigerant from the outdoor unit. The liquid refrigerant can absorb heat from air directed from the return duct 204 and across the heat exchanger 218, thereby cooling the air. As illustrated in FIGs. 2A and 2B, the heat exchanger 218 can be shaped as an “A” coil. Alternatively, the heat exchanger 218 can be shaped as an “N” or “Z” coil or “V” coil. A fan or blower 220 (referred to herein as fan 220) can direct the conditioned air (e.g., the cooled or heated air) to the interior area of a home or commercial building via the supply duct 206.

[0043] As illustrated in FIGs. 2A and 2B, the air handler 202 can include a deck 222. The deck 222 can at least partially segregate the cavity 216 into a first section and a second section. The first section can include at least the heat exchanger 218, while the second section can include at least the fan 220. The deck 222 can be affixed to the plurality of side walls 214 of the housing 208 using any attachment means (e.g., screws, fasteners, bolts, and the like). Optionally, the deck 222 can be welded to the plurality of side walls 214 of the housing 208. Optionally, the deck 222 can be removably affixed to the housing 208 such that the deck 222 can be removed from the air handler 202 to perform routine maintenance. The deck 222 can be composed of any material. For example, the deck 222 can include one or more metals. Optionally, the deck 222 can include one or more sound attenuating materials. Optionally, the deck 222 can include one or more surface features (e.g., protrusions, vanes, or the like). The deck 222 can have a shape that corresponds to the crosssection area of the air handler 202. For example, if the air handler 202 is substantially cylindrical, the deck 222 can have a substantially circular, oval, or elliptical shape. Alternatively, if the air handler 202 is a rectangular prism, the deck 222 can have a substantially rectangular or square shape. [0044] As illustrated in FIGs. 2A and 2B, the deck 222 can be positioned at an angle 224 with respect to a horizontal axis or plane. The angle 224 can be non-zero. That is, the horizontal axis or plane can intersect the air handler 202 such that the horizontal axis or plane is perpendicular to a side wall 214 of the air handler 202 and/or the horizontal axis or plane is perpendicular to a longitudinal axis of the air handler 202 (which is the same general direction as the flow of conditioned air indicated by arrow 308 in FIG. 3). For example, the deck 222 can be positioned at an angle 224 of less than or equal to approximately 50 degrees. Optionally, the deck 222 can be positioned at an angle 224 of between approximately 5 degrees and approximately 50 degrees with respect to the horizontal axis. Optionally, the deck 222 can be positioned at an angle 224 of between approximately 15 degrees and approximately 45 degrees with respect to the horizontal axis. Optionally, the deck 222 can be positioned at an angle 224 of between approximately 25 degrees and approximately 40 degrees. Optionally, the deck 222 can be positioned at an angle 224 of between approximately 30 degrees and approximately 40 degrees. As further discussed herein, by positioning the deck 222 at an angle 224, an efficient flow of air can be directed through the air handler 202 and out of the supply duct 206, thereby providing energy savings.

[0045] The deck 222 can be configured to support the fan 220. For example, the deck 222 can include an aperture 234 sized to substantially align with the inlet 228 of the fan 220. The inlet 228 of the fan 220 can receive the conditioned air that has been directed from the return duct 204 across the filter 226 and heat exchanger 218. The conditioned air can be expelled from the fan 220 and directed to the supply duct 206, and thereby into the interior area. For example, the flow of conditioned air can be expelled from the fan 220 via the spaces between the blades of an impeller 230 of the fan 220.

[0046] The deck 222 can be positioned such that one end of the deck 222 is at a first height and the other end of the deck 222 is at a second height. The second height can be greater than the first height. As such, the end of the deck 222 at the first height can be closer to the first end 210 of the air handler 202 while the other end of the deck 222 at the second height can be closer to the second end 212 of the air handler. The fan 220 can be positioned towards the end of the deck 222 that is positioned at the first height (e.g., the “lower” end of the deck 222). Alternatively, the fan 220 can be positioned towards the center of the deck 222. The fan 220 can be positioned such that the air being expelled can be directed at an angle the same as the angle 224 of the deck 222, as further discussed herein. [0047] The fan 220 can be any of a plurality of different types. In one example, the fan 220 can be an axial fan (e.g., a backward curved fan or a vane axial fan). As illustrated in FIGs. 2A and 2B, the fan 220 can be a backward curved fan. A backward curved fan can include an impeller 230 including blades that are curved in the opposite direction of the rotation of the fan. The impeller 230 can be rotated by a motor 232. Such rotation can create pressure within the air handler 202. Alternatively, the fan 220 can be a vane axial fan in which the blades are attached parallel to the direction of the rotor axis. The use of an axial fan within the air handler 202 can provide a variety of advantages as discussed further herein.

[0048] Optionally, the fan 220 can be at least partially enclosed in a fan housing. For example, the fan 220 can be disposed within a plenum chamber or scroll housing. Alternatively, fan 220 can not be enclosed in a fan housing, thereby providing costs savings due to less necessary material.

[0049] As illustrated in FIG. 2B, when the fan 220 is an axial fan the second end 212 of the air handler 202 can be substantially open due to the axial fan creating a pressure differential within the second section of the cavity 216 of the air handler 202. Such pressure differential can facilitate the flow of conditioned air being directed upward and into the supply duct 206. Optionally, the cross-section area of an opening 236 of the second end 212 can be substantially the same as the cross-section area of the second end 212. Optionally, the cross-section area of the opening 236 of the second end 212 can be greater than or equal to half of the cross-section area of the second end 212. In contrast, when a forward curved centrifugal fan is used within an air handler, at least a portion of the second end 212 of the air handler 202 may have to be enclosed in order to create a pressure differential within the cavity 216 of the air handler 202 such that the flow of air is directed into the supply duct 206. By having a substantially open second end 212 of the air handler 202, the fan 220 can operate at lower speeds, but still achieve the same air flow rate as traditional air handlers that fraction off a portion of the second end of the air handler and/or position the fan such that the outlet of the fan or fan housing is in direct communication with the supply duct 206. [0050] When the deck 222 is positioned at a non-zero angle 224 and the fan 220 is an axial fan, the fan 220 can have a larger diameter as compared to if the deck 222 was not positioned at such angle. For example, the diameter of the fan 220 can be sized such that the outer circumference of the fan 220 is less than or equal to approximately one (1) inch from one or more of the inner walls of the side walls 214 of the housing 208. Optionally, the diameter of the fan 220 can be sized such that the outer circumference of the fan 220 is between approximately one (1) inch and approximately five (5) inches from one or more of the inner walls of side walls 214 of the housing 208. In other words, the diameter of the fan 220 can be sized such that the diameter of the fan 220 is between approximately 70% and approximately 90% of the width W of the housing 208. Optionally, the diameter of the fan 220 can be sized such that the diameter of the fan 220 is between approximately 75% and approximately 85% of the width W of the housing 208. The diameter of the fan can be increased due to the axial fan creating a pressure differential within the second section of the cavity 216. As such and as explained herein, the second end 212 of the air handler 202 that is in fluid communication with the supply duct 206 can be substantially open. When the diameter of the fan 220 is increased, the speed of the fan 220 can be decreased. However, such decrease can have little to no impact on the air flow rate out of the air handler 202 and into the supply duct 206 due to the substantially open second end 212. For example, just as a forward curved centrifugal fan, the axial fan can move approximately 1200 cubic feet of air per minute.

[0051] Optionally, the fan 220 can include a variable-speed motor which can modulate the flow of air based on demand to provide an enhanced and efficient heating and/or cooling effect. The variable-speed motor can allow the fan 220 to operate at a low-speed a majority of the time, thereby providing consistent and stable temperatures within the interior area. Accordingly, a user can adjust the thermostat or other means for controlling interior air temperatures less frequently, resulting in energy savings for the user.

[0052] The air handler 202 can have various height H, width W, and length L dimensions. Optionally, the air handler 202 can have height H, width W, and length L dimensions that are substantially similar to those of a conventional air handler (e.g., air handler 102 illustrated in FIG. 1). For example, the air handler 202 can have a height H of between approximately 35 inches and approximately 70 inches, a width W of between approximately 14 inches and approximately 25 inches, and a length L of between approximately 16 inches and approximately 24 inches. By maintaining substantially similar dimensions as a conventional air handler, the air handler 202 can be installed in users’ homes and/or commercial entities without the need for extensive labor or costs, as the same sized and configurations of the return duct 204, supply duct 206, and other components of the air handler 202 can be used. [0053] FIG. 3 illustrates a schematic diagram of the flow of air within the example air handler 202. As illustrated by arrow 302, a flow of air from an interior area of a home or commercial building can be directed into the cavity 216 of the air handler 202 via the return duct 204. The heat exchanger 218 can condition (e.g., warm or cool) the flow of air as the air is being directed across the coils of the heat exchanger 218.

[0054] The flow of conditioned air can then be directed into the inlet 228 of the fan 220 as indicated by arrow 304. For example, the rotation of the impeller 230 of the fan 220 can pull the flow of conditioned air into the inlet 228 of the fan 220.

[0055] The type of fan 220 can impact the directionality of the flow of conditioned air out of the fan 220. For example, and as illustrated by arrow 306 in FIG. 3, if the fan 220 is an axial fan (e.g., a backward curved fan or a vane axial fan), the flow of conditioned air can be expelled from the fan 220 with a radial centrifugal force (e.g., at a substantially ninety-degree angle with respect to the direction of air entering the inlet 228 the fan 220) such that the flow of conditioned air is directed substantially in line with the angle 224 of the deck 222. If the deck 222 was positioned horizontally, as in traditional air handlers (e.g., air handler 102 in FIG. 1), an axial fan would inefficiently direct the flow of conditioned air from the air handler 202 into the supply duct 206, as the flow of conditioned air would be expelled substantially horizontally (e.g., parallel to the horizontal deck). As such, the flow of conditioned air would be directed towards the plurality of side walls 214 of the air handler 202 and not upward in the direction of the supply duct 206. Accordingly, by angling the fan deck 222 at an angle 224, an axial fan can be positioned within the air handler 202. Given the advantages of such axial fan as discussed herein and commonly known in the art, by utilizing an axial fan, the air handler 202 can operate in a manner that can facilitate compliance with new energy efficiency standards.

[0056] After the flow of conditioned air is expelled from the fan 220 at an angle substantially aligned with the angle 224 of the deck 222, the flow of conditioned air can be directed into the supply duct 206 as indicated by arrow 308. For example, the flow of conditioned air can be expelled from the fan 220 at an angle substantially aligned with the angle 224 of the deck 222 and once the conditioned air interacts and/or hits the side walls 214 of the housing 208, the flow of conditioned air can be directed substantially vertically as indicated by arrow 308. When the fan 220 is an axial fan, the fan itself can create pressure within the second section of the cavity 216 and such pressure differential can facilitate the flow of conditioned air being directed upward toward the supply duct 206. [0057] FIG. 4A illustrates the air handling system 200 including the example air handler 202 in an alternative position, and FIG. 4B similarly illustrates a perspective view of the air handler 202 in the alternative position. In some instances, a downward flow of air is required. For example, when an air handler 202 is installed in an attic or top portion of a home or commercial building, it can be necessary to install the supply duct 206 such that the flow of conditioned air is directed downward to the interior area of the home or commercial building. Conventionally, directing air downward required removing various components of an air handler (e.g., removing the fan and/or heat exchanger) and reinstalling such components in different positions, thereby resulting in additional costs, time, and labor. As illustrated in FIGs. 4A and 4B, the air handler 202 can be turned 180 degrees (e.g., upside down) (as compared to FIGs. 2A and 2B, for example) in order to provide a downward flow of air. Such repositioning of the air handler 202 can be performed without any alteration or reassembling of the components of the air handler 202. Accordingly, cost, time, and labor savings can be realized.

[0058] As illustrated in FIGs. 4A and 4B, the first end 210 of the housing 208 can be a top end of the air handler 202 and can be in fluid communication with the return duct 204. The second end 212 can be a bottom end of the air handler 202 and can be in fluid communication with a supply duct 206. In such configuration and as illustrated by the arrows, the air handler 202 can receive air from the return duct 204 and can direct the flow of air in a downward direction towards the supply duct 206 such that a flow of conditioned air can be supplied to an interior area.

[0059] FIG. 5 is a flow diagram outlining an example method 500 of manufacturing the example air handling system 200. The method 500 can including providing 502 a housing 208 including a first end 210, a second end 212, and a plurality of side walls 214 defining a cavity 216. The housing 208 can be made of a variety of materials. Optionally, the housing 208 can be made of one or metals that can provide thermal and/or sound insulation. For example, the housing 208 can be substantially steel and include foil insulation.

[0060] The method 500 can including positioning 504 a heat exchanger 218 within the cavity 216 of the housing 208. The heat exchanger 218 can include a plurality of coils configured to circulate liquid and vapor refrigerant such that the air received from the return duct 204 can be conditioned (e.g., cooled or heated).

[0061] The method 500 can include positioning 506 a deck 222 including an aperture 234 at a non-zero angle 224 with respect to horizontal within the cavity 216 of the housing 208 such that the deck 222 substantially divides the cavity 216 into a first section and a second section. The deck 222 can be positioned within the cavity 216 by affixing the outer circumference of the deck 222 to the inner walls of the housing 208. Any attachment means can be used to affix the deck 222 within the housing 208. Optionally, the deck 222 can be welded to the inner walls of the housing 208. Optionally, the deck 222 can be removably affixed to the inner walls of the housing 208 such that the deck 222 can be easily removed from the air handler 202 for routine maintenance.

[0062] The deck 222 can be positioned at an angle 224 of less than or equal to approximately 50 degrees, with respect to horizontal. Optionally, the deck 222 can be positioned at an angle 224 of between approximately 5 degrees and approximately 50 degrees, with respect to horizontal. Optionally, the deck 222 can be positioned at an angle 224 of between approximately 15 degrees and approximately 45 degrees with respect to the horizontal axis. Optionally, the deck 222 can be positioned at an angle 224 of between approximately 25 degrees and approximately 40 degrees. Optionally, the deck 222 can be positioned at an angle 224 of between approximately 30 degrees and approximately 40 degrees. As such, the deck 222 can be positioned such that one end of the deck 222 is at a first height and a second end of the deck 222 is at a second height where the second height is greater than the first height. According, the end of the deck 222 at the first height can be closer to the first end 210 of the air handler 202 that is in fluid communication with the return duct 204 while the other end of the deck 222 at the second height can be closer to the second end 212 of the air handler 202 that is in fluid communication with the supply duct 206. The deck 222 can be positioned such that the aperture 234 is positioned toward the end of the deck 222 that is at the “lower” first height.

[0063] The method 500 can include affixing 508 a fan 220 to the deck 222 such that an inlet 228 of the fan 220 is in fluid communication with the first section of the cavity 216 via the aperture 234. The impeller 230 of the fan 220 can be exposed to the second section of the cavity 216 such that when the flow of conditioned air is expelled from the fan 220, the flow of conditioned air remains within the second section and can be directed to the supply duct 206. The fan 220 can be affixed to the deck 222 via a plurality of attachment means (e.g., bolts, screws, and the like). Optionally, the fan 220 can be removably affixed to the deck 222 such that the fan 220 can be easily removed for routine maintenance. The fan 220 affixed to the deck 222 can be an axial fan. For example, the fan 220 can be a backward curved fan or a vane axial fan. [0064] Optionally, the method 500 can further include affixing a return duct 204 to the first end 210 of the housing 208 such that air from an interior area of a home or building can be directed into the first section of the air handler 202 via the return duct 204.

[0065] Optionally, the method 500 can further include affixing a supply duct 206 to the second end 212 of the housing 208 such that the flow of conditioned air can be directed from the air handler 202 and back into the interior area of a home or building via the supply duct 206.

[0066] Certain examples and implementations of the disclosed technology are described above with reference to block and flow diagrams according to examples of the disclosed technology. It will be understood that one or more blocks of the block diagrams and flow diagrams, and combinations of blocks in the block diagrams and flow diagrams, respectively, can be implemented by computer-executable program instructions. Likewise, some blocks of the block diagrams and flow diagrams do not necessarily need to be performed in the order presented, can be repeated, or do not necessarily need to be performed at all, according to some examples or implementations of the disclosed technology. It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Additionally, method steps from one process flow diagram or block diagram can be combined with method steps from another process diagram or block diagram. These combinations and/or modifications are contemplated herein.