Hvac base and return air system

Abstract

A base is provided for installation of an HVAC system which allows for high efficiency air intake. The HVAC base and air return system provides for intake of air simultaneously through the bottom and side of a furnace unit. The HVAC base and air return system allow for installation and use of a wider filter box.

What is claimed is: 
     
         1 . A furnace base for high efficiency airflow comprising:
 a first lateral wall member that is substantially rectangular in shape;   a second lateral wall member that is substantially rectangular in shape;   a third lateral wall member that is substantially rectangular in shape;   a bottom side member that is substantially rectangular in shape;   one or more furnace support members;   wherein the first and second wall members are configured substantially at right angles to each other and the second and third lateral wall members are configured substantially at right angles to each other, the first, second and third lateral wall members forming three lateral walls of a rectangular box;   wherein a first perimeter edge of the first lateral wall member, a first perimeter edge of the second lateral wall member, and a first perimeter edge of the third lateral wall member are respectively coupled to the bottom side member substantially along a first, second, and third perimeter edge of the bottom side member;   wherein a fourth side of the rectangular box is defined by an opening to permit air to pass through said forth side of the rectangular box;   wherein the one or more support members are disposed in an interior portion of the rectangular box for supporting a furnace unit; and   wherein one or more rims extend from a plurality of the first, second and third lateral wall members, said one or more rims configured to extend over at least a portion of a furnace unit.   
     
     
         2 . The furnace base of  claim 1 , wherein at least one or more of the first, second and third lateral wall members, the bottom side member, the one or more furnace support members, and the one or more rims configured to extend over at least a portion of a furnace unit are comprised of a temperature resistant material. 
     
     
         3 . The furnace base of  claim 2 , wherein the temperature resistant material is a high-composite polymer. 
     
     
         4 . The furnace base of  claim 2 , wherein the temperature resistant material is a heat resistant plastic. 
     
     
         5 . The furnace base of  claim 1 , wherein at least one or more of the first, second and third lateral wall members, the bottom side member, the one or more furnace support members, and the one or more rims configured to extend over at least a portion of a furnace unit are comprised of a castable material. 
     
     
         6 . The furnace base of  claim 1 , wherein at least one or more of the first, second and third lateral wall members, the bottom side member, the one or more furnace support members, and the one or more rims configured to extend over at least a portion of a furnace unit are comprised of a machinable material. 
     
     
         7 . The furnace base of  claim 1 , wherein the first, second and third lateral wall members, the bottom side member, the one or more furnace support members, and the one or more rims configured to extend over at least a portion of a furnace unit comprise a singularly cast body. 
     
     
         8 . The furnace base of  claim 1 , wherein the first, second and third lateral wall members, the bottom side member, the one or more furnace support members, and the one or more rims configured to extend over at least a portion of a furnace unit comprise a singularly machined body. 
     
     
         9 . A high-efficiency HVAC return air system comprising:
 a furnace base comprised of a singularly cast rectangular body wherein said singularly cast rectangular body includes a first lateral side defined by an opening to permit air to pass through said first lateral side of the furnace base, one or more interior braces for supporting a furnace unit, and second, third, and fourth lateral side members forming second, third, and fourth lateral walls which extend to form a rim above the one or more interior braces;   a furnace unit including an opening through a first lateral side of said furnace unit to permit air to pass through the first lateral side of the furnace unit and an opening through a bottom side of said furnace unit to permit air to pass through the bottom side of the furnace unit;   wherein the furnace unit is disposed on the furnace base so that the rim of the furnace base covers at least a portion of the furnace unit, and wherein the furnace unit and furnace base are configured so that the first lateral side of the furnace base and the first lateral side of the furnace unit are substantially adjacent and parallel to each other;   a filter box having a first lateral side simultaneously disposed over the opening in the first lateral side of the furnace and over the opening forming the first lateral side of the furnace base; and   a return air duct having an air return opening disposed to a second lateral side of the filter box;   wherein the return air duct, the filter box, the furnace unit, and the furnace base are configured to permit air to flow from the return air duct into the filter box and then pass simultaneously through the first lateral side of the furnace unit and the bottom side of the furnace unit.   
     
     
         10 . The high-efficiency HVAC return air system of  claim 9 , wherein the width of the filter box between the return air duct and the furnace unit is about 5 inches. 
     
     
         11 . The high-efficiency HVAC return air system of  claim 9 , wherein the vertical height of the furnace base is about four inches. 
     
     
         12 . The high-efficiency HVAC return air system of  claim 9 , wherein at least one of the one or more interior braces is A-frame shaped. 
     
     
         13 . The high-efficiency HVAC return air system of  claim 9 , wherein at least one of the one or more interior braces is tubular-shaped. 
     
     
         14 . A method of installing an HVAC system comprising:
 selecting a furnace base having a singularly cast rectangular body wherein said singularly cast rectangular body includes a first lateral side defined by an opening to permit air to pass through said first lateral side of the furnace base, one or more interior braces for supporting a furnace unit, and second, third, and fourth lateral side members forming second, third, and fourth lateral walls which extend to form a rim above the one or more interior braces;   selecting a furnace unit having an opening through a first lateral side of said furnace unit to permit air to pass through the first lateral side of the furnace unit and an opening through a bottom side of said furnace unit to permit air to pass through the bottom side of the furnace unit;   disposing the furnace unit on the on the one or more interior braces in the furnace base so that the rim of the furnace base covers at least a portion of the furnace unit and so that the first lateral side of the furnace base and the first lateral side of the furnace unit are substantially adjacent and parallel to each other.   
     
     
         15 . The method of  claim 14 , wherein the method further comprises:
 selecting a filter box and disposing a first lateral side of the filter box simultaneously over the opening in the first lateral side of the furnace unit and the opening forming the first lateral side of the furnace base; and   selecting a return air duct having an air return opening and disposing the air return opening of the return air duct to a second lateral side of the filter box.   
     
     
         16 . The method of  claim 14 , wherein the method further comprises:
 selecting a sealant;   selecting one or more junctions between the furnace base and the furnace unit; and   applying the sealant to the one or more junctions between the furnace base and the furnace unit.   
     
     
         17 . The method of  claim 15 , wherein the sealant is silicone. 
     
     
         18 . The method of  claim 15 , wherein the sealant is mastic.