Modular Bulkhead System

Abstract

A structural support system for a fan array system. The system allows for a modular bulkhead wall to be customized and installed within a cabinet of an air handling unit. The modular bulkhead wall comprises one or more intermediate bulkhead stiffening elements that enable the modular bulkhead wall to support the fan array system.

The inventor claims: 
     
         1 . An HVAC modular bulkhead system for support of one or more suspended fans comprising:
 a modular bulkhead wall;   wherein the modular bulkhead wall further comprises a plurality of interlocking vertical panels;   wherein the plurality of interlocking vertical panels are aligned side-by-side substantially perpendicular to the longitudinal direction of an airstream;   wherein the one or more suspended fans produce the airstream in the longitudinal direction;   wherein the plurality of interlocking vertical panels further comprise a first side panel, a second side panel, and at least one middle panel;   wherein the at least one middle panel is configured as a fan panel;   wherein the fan panel includes at least one panel opening;   wherein the fan panel is configured to support attachment of one or more of the suspended fans;   wherein the first side panel provides a frame attachment end and a stiffening flange;   wherein the second side panel provides a frame attachment end and a c-channel;   wherein the at least one middle panel provides a stiffening flange and a c-channel;   wherein the stiffening flange of the first side panel interlocks and attaches with the c-channel of the at least one middle panel;   wherein the stiffening flange of the at least one middle panel interlocks and attaches with the c-channel of the second side panel;   wherein a tubular intermediate bulkhead stiffening element is formed by the interlocking and attachment of the stiffening flange and the c-channel of adjacent panels.   
     
     
         2 . The modular bulkhead system of  claim 1 , wherein a structural frame is secured to the first side panel, the at least one middle panel, and the second side panel. 
     
     
         3 . The modular bulkhead system of  claim 1 , wherein a transition frame is secured to the first side panel, the at least one middle panel, and the second side panel. 
     
     
         4 . The modular bulkhead system of  claim 1 , wherein a quick-connect box is attached to the modular bulkhead wall. 
     
     
         5 . The modular bulkhead system of  claim 1 , wherein the c-channel includes a c-channel lip configured as an attachment surface for between adjacent panels. 
     
     
         6 . The modular bulkhead system of  claim 5 , wherein the c-channel lip is disposed within the tubular intermediate bulkhead stiffening element. 
     
     
         7 . The modular bulkhead system of  claim 5 , wherein a front surface of the c-channel lip abuts a back surface of the adjacent panel once the panels are interlocked and attached. 
     
     
         8 . The modular bulkhead system of  claim 5 , wherein each c-channel lip is attached to an adjacent panel by fasteners that are connected through aligned pre-punched holes disposed in the c-channel lip and in the adjacent panel. 
     
     
         9 . The modular bulkhead system of  claim 1 , wherein the at least one middle panel includes at least one filler panel, and wherein each of the stiffening flange and the c-channel of the at least one filler panel interlock and attach with each of the corresponding stiffening flange or c-channel of the adjacent panels. 
     
     
         10 . The modular bulkhead system of  claim 9 , wherein the at least one filler panel is configured to provide a bulkhead door. 
     
     
         11 . The modular bulkhead system of  claim 1 , wherein at least one ledge is provided beneath the at least one panel opening of the fan panel. 
     
     
         12 . An HVAC modular bulkhead system for support of one or more suspended fans comprising:
 a modular bulkhead wall;
 wherein the modular bulkhead wall further comprises a plurality of interlocking vertical panels; 
 wherein the plurality of interlocking vertical panels are aligned side-by-side substantially perpendicular to the longitudinal direction of an airstream; 
 wherein the one or more suspended fans produce the airstream in the longitudinal direction; 
 wherein the plurality of interlocking vertical panels further comprise a first side panel, a second side panel, and at least one middle panel; 
 wherein the at least one middle panel is configured as a fan panel; 
 wherein the fan panel includes at least one panel opening; 
 wherein the fan panel is configured to support attachment of one or more of the suspended fans; 
 wherein the first side panel provides a frame attachment end and a stiffening flange; 
 wherein the second side panel provides a frame attachment end and a c-channel; 
 wherein the at least one middle panel provides a stiffening flange and a c-channel; 
 wherein the stiffening flange of the first side panel interlocks and attaches with the c-channel of the at least one middle panel; 
 wherein the stiffening flange of the at least one middle panel interlocks and attaches with the c-channel of the second side panel; 
 wherein an intermediate bulkhead stiffening element is formed by the interlocking and attachment of the stiffening flange and the c-channel of adjacent panels; and 
   one or more fans;
 wherein the one or more fans each has an integrally attached fan plate; 
 wherein, during suspension of the one or more integrally attached fan and fan plate on the fan panel, the fan plate covers the at least one fan panel opening and is attached thereto and provides support for suspension of the at least one fan from the at least one fan panel. 
   
     
     
         13 . The modular bulkhead system of  claim 12 , wherein a frame is secured to the first side panel, the at least one middle panel, and the second side panel. 
     
     
         14 . The modular bulkhead system of  claim 13 , wherein the frame is one of either a structural frame or a transition frame. 
     
     
         15 . The modular bulkhead system of  claim 12 , wherein a quick-connect box is attached to the modular bulkhead wall. 
     
     
         16 . The modular bulkhead system of  claim 12 , wherein the c-channel includes a c-channel lip configured as an attachment surface for the adjacent panel. 
     
     
         17 . The modular bulkhead system of  claim 12 , wherein the at least one middle panel includes at least one filler panel, and wherein each of the stiffening flange and the c-channel of the at least one filler panel interlock and attach with each of the corresponding stiffening flange or c-channel of the adjacent panels. 
     
     
         18 . The modular bulkhead system of  claim 12 , wherein at least one ledge is provided beneath the at least one panel opening of the fan panel. 
     
     
         19 . A method of installing an HVAC modular bulkhead system for support of one or more suspended fans within an air handling unit cabinet comprising:
 Obtaining the HVAC modular bulkhead system of  claim 12 ;   Positioning the plurality of interlocking vertical panels to be aligned side-by-side substantially perpendicular to the longitudinal direction of the suspended fan airstream;   Attaching the frame attachment end of the first side panel to a frame of the cabinet;   Securing the top and bottom ends of the first side panel to the frame of the cabinet;   Attaching the c-channel of the at least one middle panel to the stiffening flange of the first side panel;   Securing the top and bottom ends of the at least one middle panel to the frame of the cabinet;   Attaching the c-channel of the second side panel to the stiffening flange of the at least one middle panel;   Attaching the frame attachment end of the second side panel to a frame of the cabinet;   Securing the top and bottom ends of the second side panel to the frame of the cabinet, thereby forming the modular bulkhead wall;   Suspending each of the one or more integrally attached fan and fan plate on each of the fan panels such that the fan plate covers the at least one fan panel opening; and   Attaching each of the fan plates to the fan panels, thereby supporting suspension of each of the at least one fan from the at least one fan panel.   
     
     
         20 . The method of installing the HVAC modular bulkhead system of  claim 19 , further including the step of attaching a quick-connect box to the modular bulkhead wall.