Air handler with a leak free controls enclosure

Abstract

An air handler configured with a second enclosure disposed within the first enclosure to create a continuous airflow passageway, wherein access to the second enclosure does not interrupt the continuous airflow passageway.

What is claimed is: 
     
         1 . An air handler comprising:
 a first enclosure having a first interior volume;   a second enclosure having a second interior volume; and   wherein the second enclosure is affixed to the first enclosure such that the second interior volume is disposed within the first interior volume;   
     
     
         2 . The air handler of  claim 1 , further comprising:
 at least one component disposed within the second interior volume;   a fan disposed within the first interior volume;   wherein the at least one component is in operable communication with the fan; and   wherein the at least one component is operative to control the fan to cause air to move through the first enclosure.   
     
     
         3 . The air handler of  claim 1 , further comprising a coil disposed within the first interior volume. 
     
     
         4 . The air handler of  claim 3 , wherein the coil is configured to allow a refrigerant to flow therethrough. 
     
     
         5 . The air handler of  claim 4 , wherein the second enclosure is affixed to the first enclosure above the coil. 
     
     
         6 . The air handler of  claim 1 , wherein the second enclosure is affixed to the first enclosure via at least one fastener. 
     
     
         7 . The air handler of  claim 1 , wherein an insulation material is affixed to at least one exterior side of the second enclosure. 
     
     
         8 . The air handler of  claim 7 , wherein the insulation material comprises a foam material. 
     
     
         9 . The air handler of  claim 1 , wherein at least one side of the second enclosure is removable. 
     
     
         10 . The air handler of  claim 2 , wherein the at least one component comprises a controller. 
     
     
         11 . An HVAC system comprising:
 an air handler comprising:
 a first enclosure having a first interior volume; 
 a coil disposed within the first interior volume; and 
 a second enclosure having a second interior volume; 
 wherein the second enclosure is affixed to the first enclosure such that the second interior volume is disposed within the first interior volume; 
   wherein the air handler is disposed inside an interior space.   
     
     
         12 . The HVAC system of  claim 11 , further comprising an outdoor unit assembly operatively coupled to the air handler for exchange of a refrigerant therebetween. 
     
     
         13 . The HVAC system of  claim 11 , further comprising at least one conduit affixed to the air handler to distribute air to the interior space. 
     
     
         14 . The HVAC of  claim 11 , wherein the second enclosure is affixed to the first enclosure via at least one fastener. 
     
     
         15 . The HVAC system of  claim 11 , wherein the second enclosure is affixed to the first enclosure above the coil. 
     
     
         16 . The HVAC system of  claim 11 , wherein an insulation material is affixed to at least one exterior side of the second enclosure. 
     
     
         17 . The HVAC system of  claim 16 , wherein the insulation material comprises a foam material. 
     
     
         18 . The HVAC system of  claim 11 , wherein at least one side of the second enclosure is removable. 
     
     
         19 . An air handler comprising:
 a first enclosure having a first enclosure interior volume;   a second enclosure, having a second enclosure interior volume, disposed within the first enclosure to create a continuous airflow passageway;   wherein access to the second enclosure interior volume does not interrupt the continuous airflow passageway.