Heating element assemblies for air handling units

Abstract

The disclosed technology includes an axial fan assembly for an air handling unit. The axial fan assembly can include an axial fan that is configured to direct a flow of air along an airflow path through the axial fan assembly and a stator that is disposed in the airflow path downstream of the axial fan to at least partially straighten the flow of the air. The axial fan assembly can include a heating element assembly disposed in the airflow path downstream of the stator. The heating element assembly can include a heating element having a generally toroidal shape having an outer diameter less than an inner diameter of a casing disposed around the axial fan. The heating element assembly can have one or more supports configured to space the heating element a distance downstream from the stator to form a gap between the stator and the heating element.

1 . An axial fan assembly for an air handling unit, the axial fan assembly comprising:
 an axial fan configured to direct a flow of air along an airflow path through the air handling unit;   a stator disposed in the airflow path downstream of the axial fan, the stator being configured to at least partially straighten the flow of the air; and   a heating element assembly disposed in the airflow path downstream of the stator, the heating element assembly comprising:
 a heating element having a generally toroidal shape, the generally toroidal shape having an outer diameter that is less than an inner diameter of a casing disposed around the axial fan; and 
 one or more supports configured to space the heating element a distance downstream from the stator to form a gap between the stator and the heating element. 
   
     
     
         2 . The axial fan assembly of  claim 1 , wherein the gap is approximately six inches from the stator. 
     
     
         3 . The axial fan assembly of  claim 1 , wherein the heating element is a first heating element, and
 wherein the heating element assembly further comprises a second heating element, the one or more supports being configured to space the second heating element the distance downstream from the stator forming a gap between the stator and the second heating element.   
     
     
         4 . The axial fan assembly of  claim 3 , wherein the first heating element and second heating element are coaxial. 
     
     
         5 . The axial fan assembly of  claim 3 , wherein the first heating element and the second heating element are coplanar. 
     
     
         6 . The axial fan assembly of  claim 1 , wherein the one or more supports are attached to the stator. 
     
     
         7 . The axial fan assembly of  claim 6 , wherein the one or more supports comprise a plurality of vertical supports attached to the stator and extending upward to the heating element, the plurality of vertical supports being configured to support the heating element. 
     
     
         8 . The axial fan assembly of  claim 7 , wherein the plurality of vertical supports comprise a clip configured to attach the plurality of vertical supports to the stator. 
     
     
         9 . The axial fan assembly of  claim 1 , wherein the one or more supports comprise a central support hub and central supports extending radially outward from the central support hub to the heating element assembly, the central supports being configured to support the heating element. 
     
     
         10 . The axial fan assembly of  claim 9 , wherein the central support hub is attached to a central hub of the stator. 
     
     
         11 . The axial fan assembly of  claim 1 , wherein the one or more supports comprise a plurality of lateral supports extending radially inward from a casing disposed around the axial fan and the stator, the plurality of lateral supports configured to support the heating element. 
     
     
         12 . The axial fan assembly of  claim 1 , wherein the heating element assembly is disposed at least partially within an outlet nozzle of the axial fan assembly, the outlet nozzle being disposed downstream of the axial fan and the stator. 
     
     
         13 . The axial fan assembly of  claim 12 , wherein the outlet nozzle comprises an inlet having a first diameter and an outlet having a second diameter, the second diameter being greater than the first diameter. 
     
     
         14 . The axial fan assembly of  claim 13 , wherein the outlet nozzle further comprises an integrated heating element that is configured to heat the outlet nozzle. 
     
     
         15 . The axial fan assembly of  claim 1 , wherein the stator further comprises vanes having an integrated heating element assembly disposed in a vane of the stator. 
     
     
         16 . The axial fan assembly of  claim 1 , wherein the stator further comprises vanes having an integrated heating element assembly disposed along an outer surface of the stator. 
     
     
         17 . The axial fan assembly of  claim 16 , wherein the integrated heating element assembly comprises a thermally-conductive ceramic material. 
     
     
         18 . The axial fan assembly of  claim 1  further comprising a heat shield disposed between the heating element assembly and an electrical motor of the axial fan. 
     
     
         19 . A heating element assembly for an air handling unit, the heating element assembly comprising:
 a resistive heating element comprising a generally toroidal shape, the generally toroidal shape having an outer diameter that is less than an inner diameter of a casing disposed around an axial fan;   a central support hub disposed proximate a center of the resistive heating element; and   a plurality of central supports extending radially outward from the central support hub to the resistive heating element, the plurality of central supports being configured to support the resistive heating element.   
     
     
         20 . The heating element assembly of  claim 19 , wherein the resistive heating element is a first resistive element, and
 wherein, the heating element assembly further comprises a second resistive heating element assembly, the plurality of central supports extending radially outward from the central support hub to the second resistive heating element and configured to support the second resistive heating element, wherein the first resistive heating element assembly and second resistive heating element assembly are coaxial.   
     
     
         21 .- 27 . (canceled)