U.S. patent application number 09/997596 was filed with the patent office on 2003-05-29 for hybrid window/split air treatment appliance.
Invention is credited to Cur, Nihat O., LeClear, Douglas David, Litch, Andrew David, Pastryk, Jim J., Wu, Guolian.
Application Number | 20030097854 09/997596 |
Document ID | / |
Family ID | 25544192 |
Filed Date | 2003-05-29 |
United States Patent
Application |
20030097854 |
Kind Code |
A1 |
Cur, Nihat O. ; et
al. |
May 29, 2003 |
HYBRID WINDOW/SPLIT AIR TREATMENT APPLIANCE
Abstract
The invention includes a saddle air conditioner. The saddle air
conditioner includes a remote unit having a first channel extending
from a back of the remote unit. The saddle air conditioner also
includes a local unit having a second channel extending from a back
of the local unit. The first channel and the second channel overlap
to form a bridge disposed between the remote unit and the local
unit.
Inventors: |
Cur, Nihat O.; (St. Joseph,
MI) ; Wu, Guolian; (St. Joseph, MI) ; LeClear,
Douglas David; (Coloma, MI) ; Litch, Andrew
David; (St. Joseph, MI) ; Pastryk, Jim J.;
(Sawyer, MI) |
Correspondence
Address: |
WHIRLPOOL PATENTS COMPANY - MD 0750
500 RENAISSANCE DRIVE - SUITE 102
ST. JOSEPH
MI
49085
US
|
Family ID: |
25544192 |
Appl. No.: |
09/997596 |
Filed: |
November 29, 2001 |
Current U.S.
Class: |
62/262 ;
62/298 |
Current CPC
Class: |
F24F 1/027 20130101 |
Class at
Publication: |
62/262 ;
62/298 |
International
Class: |
F25D 023/12; F25D
019/00 |
Claims
What is claimed is:
1. A local unit of an air treatment appliance comprising: an air
moving device that can be configured as part of a window air
conditioner; a split air conditioner, or an air purifier
2. The local unit of claim 1, having a first blower wheel and a
second blower wheel, wherein each of the first blower wheel and the
second blower wheel define a vertical axis of rotation.
3. The local unit of claim 1, wherein the window air conditioner is
configured as a saddle air conditioner.
4. The local unit of claim 1, split air conditioner comprising: the
local unit having a first blower wheel and a second blower wheel,
wherein each of the first blower wheel and the second blower wheel
defines a vertical axis of rotation; a remote unit; and a supply
system disposed between the first unit and the second unit.
5. The split air conditioner of claim 4, further comprising: a
shroud disposed about the first blower wheel and the second blower
wheel.
6. The split air conditioner of claim 5, wherein the shroud is a
continuous formed sheet having a wall that divides the first blower
wheel from the second blower wheel.
7. The split air conditioner of claim 6, wherein the shroud further
includes a first curved portion coupled between the wall and a
first channel and includes a second curved portion coupled between
the wall and a second channel
8. A fan motor system for the local unit of claim 3, the fan motor
system comprising: a fan having a shaft; a first pulley wheel
coupled to the shaft of the fan; a motor having a shaft, wherein
the motor includes a plurality of poles and wherein the number of
poles is less than six; a second pulley wheel coupled to the shaft
of the motor; and a pulley belt disposed between the first pulley
wheel and the second pulley wheel,
9. The fan motor system of claim 8, wherein the ratio of a diameter
of the first pulley wheel to a diameter of the second pulley wheel
is in the range of about 3:1 to 3:2.
10. An installation bracket for a split air conditioner, the
bracket comprising: a local frame having a first bar coupled at
ninety degrees to a first leg, a second bar coupled at ninety
degrees to a second leg, a local crossbar coupled between the first
bar and the second bar, and a brace coupled between the first leg
and the second leg, wherein the first bar and the second bar each
have a slot; a remote frame having a first bar coupled at ninety
degrees to a first leg, a second bar coupled at ninety degrees to a
second leg, a remote crossbar coupled between the first bar and the
second bar, wherein the first bar and the second bar of the remote
frame each includes a plurality of holes, wherein the first leg of
the remote frame includes a first foot and the second leg of the
remote frame includes a second foot, wherein each foot extends
ninety degrees from an associated leg, the remote frame further
having a brace coupled between the first foot and the second foot
and at least two spacers coupled to the brace of the remote frame;
and at least one connector disposed through each slot of the local
frame and a hole of the remote frame.
11. The bracket of claim 10 wherein the remote frame further
includes a first rib and a second rib, each disposed between the
first leg and the second leg of the remote frame.
12. The bracket of claim 11, wherein the first rib, the first leg,
the brace, and the second leg of the remote frame define an opening
that is divided by the second rib of the remote frame, wherein a
height of the opening is ninety percent of a height of the first
leg.
13. An air conditioner system, comprising: an installation bracket
that is adapted to be disposed over a wall; and a saddle air
conditioner disposed over the installation bracket, the saddle air
conditioner having a remote unit coupled to a local unit with a
bridge, wherein the remote unit includes a back having at least one
grill that is adapted to permit air to pass through the back of the
remote unit into the remote unit of the saddle air conditioner.
14. The air conditioner system of claim 13, wherein the
installation bracket includes: a local frame coupled to a remote
frame, the local frame having a first bar coupled at ninety degrees
to a first leg, a second bar coupled at ninety degrees to a second
leg, a local crossbar coupled between the first bar and the second
bar, and a brace coupled between the first leg and the second leg,
wherein the first bar and the second bar each have a slot, the
remote frame having a first bar coupled at ninety degrees to a
first leg, a second bar coupled at ninety degrees to a second leg,
a remote crossbar coupled between the first bar and the second bar,
wherein the first bar and the second bar of the remote frame each
includes a plurality of holes, wherein the first leg of the remote
frame includes a first foot and the second leg of the remote frame
includes a second foot, wherein each foot extends ninety degrees
from an associated leg, the remote frame further having a brace
coupled between the first foot and the second foot and at least two
spacers coupled to the brace of the remote frame, and at least one
bolt disposed through each slot of the local frame and a hole of
the remote frame.
15. The air conditioning system of claim 13, wherein a distance
between the brace of the remote frame and the wall is at least
fifty to seventy percent of a distance between the first leg of the
remote frame and the wall and wherein the interior of the remote is
not adapted to receive air from a top of the remote unit.
16. A saddle air conditioner, comprising: local unit and a remote
unit; the remote unit having a first channel extending from a back
of remote unit; and the local unit having a second channel
extending from a back of the local unit, wherein the first channel
and the second channel overlap to form a bridge disposed between
the remote unit and the local unit.
17. The saddle air conditioning of claim 16, wherein the local unit
defines a length, wherein the first channel is an interior tray and
the second channel is an exterior tray, wherein a length of the
exterior tray is approximately the same as the length of the local
unit, the saddle air conditioner fur comprising: a cover disposed
over the exterior tray and the interior tray.
18. The saddle air conditioner of claim 17, wherein the interior
tray includes a base disposed between a first lip and a second lip,
wherein each of the first lip and the second lip include a
plurality of holes, wherein the exterior tray includes a base
disposed between a first lip and a second lip, wherein each of the
first lip and the second lip of the exterior tray include a slot,
the saddle air conditioner further comprising: at lease one
connector through the slot of the first lip and the second lip of
the exterior tray.
19. The saddle air conditioner of claim 16, further comprising: a
helical tubing disposed within the bridge between the local unit
and the remote unit.
Description
[0001] The invention includes arrangements to substantially improve
customer benefits in window air conditioning and at the same time
to reduce assembly and installation requirements and operating
noise for a cooling and/or ventilating air treatment appliance.
BACKGROUND OF THE INVENTION
[0002] To cool a certain location such as the room of a home, an
air cooling unit of an air conditioning system (or "air
conditioner") may draw heat from the room into a coolant working
fluid. To expel the heat absorbed into the fluid, the air
conditioner may route that heated coolant to a location that is
remote from the room. There, a heat discharging unit may expel the
heat from the coolant into the remote location, typically
outdoors.
[0003] Conventional room air conditioners may be categorized into
window or split air conditioners. A unitary air conditioner may be
a unit in which the air cooling unit and the heat discharging
outdoor unit are fixed relative to one another to form a single
housing. A split air conditioner may be a unit in which the
position of the air cooling unit relative to the heat discharging
outdoor unit may be varied.
[0004] In the area of split air conditioners, assembly,
installation, and operating noise are major concerns for customers
who purchase air conditioners. One type of split air conditioner is
a saddle mount air conditioner. A saddle mount air conditioner may
include a low profile service channel disposed between an indoor,
air cooling unit and an outdoor, heat discharging unit to permit
air, condensate water, coolant, and electricity to pass between
each unit. The service channel may be placed on the sill of a
window so that the indoor unit and the outdoor unit straddle the
sill at locations that are significantly below the horizontal level
of the sill.
[0005] A problem with conventional window as well as split air
conditioners, is they are difficult to assemble and install. For
example, service channels of conventional split air conditioners
are banded tubes that are pre-charged with working fluid, expensive
and limited in their ability to adjust to fit a variety of home
constructions. Moreover, heavy, bulky, heat discharging outdoor
units of split air conditioners increase the cost of installation.
It is desirable that the connecting tube between the heat transfer
coils of a split air conditioner be charged with coolant at the
factory and that the various auxiliary service tubing be connected
at the factory rather than the home of the consumer. However, due
to the design of conventional service channels, professional
on-site installation is necessary to connect the air, water,
coolant, and electrical service lines between the indoor unit and
the outdoor unit.
[0006] In operation, conventional split air conditioners produce a
great amount of noise that finds its way into the inside of a
consumer's home. For example, noise from air drawn into the top of
the heat discharging unit is propagated through the window glass to
the inside of a consumer's home. Also, for window air conditioners
in general, an ongoing problem is the noise generated by the
components of the air cooling unit located within the consumer's
home. Air cooling unit components such as the evaporator fan motor,
the speed of the evaporator fan, the arrangement of the evaporator
fan, and the condensate removal system each generate noise which is
propagated into the room.
[0007] It is desirable to have a hybrid room air conditioner that
can be configured either as a saddle mount air conditioner which
gives customers full access to the window without obstruction or
can be assembled as a conventional split or portable air
conditioner. It is also desirable to have a unique mechanism that
makes the saddle window air conditioner installation simple and
easy.
SUMMARY OF THE INVENTION
[0008] The invention includes a local unit that may be utilized to
provide local cooling and/or air purifying. The local unit may
function as the cooling function for a split air conditioner, or a
window unit such as a portable air conditioner or a saddle air
conditioner. The local unit functions to draw air in a frontal
portion and to exit the air out a peripheral portion, thus allowing
the unit to be utilized in the same vertical orientation regardless
of the configuration of the overall units.
[0009] In a preferred embodiment, the local unit is configured with
two vertically disposed cross flow fans to draw air from the room,
over the evaporator and exhaust the cooled air out through the
periphery of the local unit. A similarly configured local unit
includes an axial flow or centrifugal fan (herein after "fan") that
may be driven directly or indirectly by an electric motor.
[0010] In a saddle mount air conditioner configuration, an
installation bracket is provided with the saddle air conditioner
disposed over the installation bracket, the saddle air conditioner
having a remote unit coupled to a local unit with a bridge, and
wherein the remote unit includes a back having at least one grill
that is adapted to permit air to pass through the back of the
remote unit into the remote unit of the saddle air conditioner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 illustrates split air conditioner incorporating
principles of the invention;
[0012] FIG. 2 illustrates an air conditioner system;
[0013] FIG. 2A is a sectional view of a supply cable taken
generally along line IIA-IIA of FIG. 2;
[0014] FIG. 3 illustrates a perspective view of a portable air
conditioner;
[0015] FIG. 4 illustrates a perspective view of a saddle air
conditioner;
[0016] FIG. 5 is a perspective view of a beam taken generally along
line VA-IVA of FIG. 4;
[0017] FIG. 6 illustrates a perspective view of the saddle air
conditioner with a cover removed;
[0018] FIG. 7 illustrates flexible tubing disposed within the
bridge;
[0019] FIG. 8 illustrates helical tubing;
[0020] FIG. 9 illustrates serpentine tubing;
[0021] FIG. 10 illustrates roll tubing;
[0022] FIG. 11 illustrates an installation of the saddle air
conditioner;
[0023] FIG. 12 illustrates a gap filler having one cutout;
[0024] FIG. 13 illustrates the gap filler having two cutouts;
[0025] FIG. 14 illustrates the saddle air conditioner with an
exterior tray and the majority of the remote unit removed to reveal
a Z-bracket;
[0026] FIG. 15 is an exploded view of the local unit of FIG.
14;
[0027] FIG. 16 is a front view of the local unit;
[0028] FIG. 16A is a sectional view of the local unit taken
generally along line XVIA-XVIA of FIG. 16;
[0029] FIG. 16B is a sectional view of the local unit taken
generally along line XVIB-XVIB of FIG. 16;
[0030] FIG. 17 is a top view of the local unit;
[0031] FIG. 18 illustrates an exploded, perspective view of a fan
motor system;
[0032] FIG. 19 illustrates a first blower wheel and a second blower
wheel disposed in a unit of a split air conditioner;
[0033] FIG. 20 illustrates the first blower wheel and the second
blower wheel disposed behind an evaporator coil;
[0034] FIG. 21 is a perspective view of the local unit with the
first blower wheel and the second blower wheel removed to reveal a
shroud;
[0035] FIG. 22 is a perspective view of the local unit with the
shroud removed to reveal a first motor and a second motor;
[0036] FIG. 22A schematically illustrates a blower wheel motor
system;
[0037] FIG. 23 is a perspective view of the saddle air conditioner
with parts removed to reveal details of a remote unit;
[0038] FIG. 24 is a detailed view of the remote unit with condenser
tubes removed;
[0039] FIG. 25 illustrates an installation bracket of the
invention;
[0040] FIG. 26 illustrates an installation bracket disposed over a
bottom rail (FIG. 11);
[0041] FIG. 27 illustrates the saddle air conditioner disposed over
the installation frame; and
[0042] FIG. 28 illustrates an air path with respect to the remote
unit.
DETAILED DESCRIPTION OF THE INVENTION
[0043] FIG. 1 illustrates a split air conditioner embodying
principles of the present invention. Included with the air
conditioner 10 may be a local unit 12 and a remote unit 14. The
local unit 12 may include an evaporator system that both absorbs
heat from the surrounding environment into a working fluid and
passes that heated fluid to the remote unit 14. The remote unit 14
may include a condenser system that may expel heat from the fluid
to aid in cooling the fluid, whereupon the fluid may be
recirculated to the local unit 12.
[0044] Coupled between the local unit 12 and the remote unit 14 may
be a supply system 16. The supply system 16 may include an
adjustable structure that aids in routing tubing, such as air,
condensate water, coolant, and electricity tubing, between the
local unit 12 and the remote unit 14. Under this arrangement, the
air conditioner 10 may be viewed as a split air conditioner. Here,
the adjustibility of the supply system 16 may permit a user to
position the local unit 12 in any one of a number of orientations
with respect to the remote unit 14. As schematically illustrated in
FIG. 1, the air conditioner 10 may include a mini-split air
conditioner 26 of FIG. 2, a portable air conditioner 80 of FIG. 3,
a saddle air conditioner 100 of FIG. 4 and FIG. 5, or the local
unit may be utilized as an air purifier as exemplified in FIG.
15.
[0045] FIG. 2 illustrates an air conditioner system 20. Included
with the air conditioner system 20 may be a wall or walls 22, a
surface 24, and the mini-split air conditioner 26. The walls 22 may
meet with a ceiling (not shown) and the surface 24 so as to define
an area (here, an indoors area 28) that may be distinguished from
an outdoor area 30. The indoor area 28 may be an area within a
building enclosed by the walls 22 and the surface 24 and a ceiling.
The walls 22 may include a window 32 so that the indoor area 28
need not be completely isolated from the outdoor area 30 area.
Moreover, the outdoor area 30 may include any location that is
remote from the indoor area 28, even where a structure does not
exist to physically separate the two areas.
[0046] The mini-split air conditioner 26 may include a local unit
34, a remote unit 36, and a supply cable 38. In the view shown in
FIG. 2, the local unit 34 may include a front grill 39, a first
louver 40, and a second louver 92 (FIG. 15), each disposed within
or as part of a housing 42. The front grill 39 may be any network
of fixed or movable slats that define a mesh of openings to pass
air. The first louver 40 may be any framed opening fitted with
fixed or movable slats to pass air.
[0047] In the view shown in FIG. 2, the remote unit 36 may include
a front grill 43, a first louver 41 (FIG. 6), and a second louver
44, each disposed within or as part of a housing 46. The front
grill 43 and the second louver 44 may be similar to the front grill
39 and first louver 40, respectively. Moreover, the slats of the
front grill 43 and the second louver 44 may be arranged to shed
rain so that the housing 46 works to repel water without allowing
rain to penetrate within the housing 46.
[0048] FIG. 2A is a sectional view of a supply cable 38 taken
generally along line IIA-IIA of FIG. 2. The supply cable 38 may be
viewed as an umbilical cord that works towards providing auxiliary
services between the local unit 34 and the remote unit 36. The
supply cable 38 may include a sleeve 48. The sleeve 48 may be any
tubular construction designed to cover other parts. Alternatively,
the sleeve 48 may be a series of ties that bundle other parts
together. Moreover, the sleeve 48 may include insulation disposed
about its interior or exterior surface.
[0049] The sleeve 48 may be flexible or rigid through structural
design, selection of material, or a combination of the two. For
example, the sleeve 48 may be made from corrugated tubing
surrounded by a polyethylene non-chlorinated jacket. The material
of the sleeve 48 may include at least one of plastic, rubber,
cloth, metal, polyvinyl chloride (PVC), and wood. When made of a
rigid material, the sleeve 48 may include joints, mating pieces,
and elongated pieces of varying lengths to permit a user to
position the local unit 34 in any one of a number of orientations
with respect to the remote unit 36. In the embodiment shown in FIG.
2A, the sleeve 48 is made of copper.
[0050] The supply cable 38 may also include power lines 50, a
suction line 52, and an expansion line 54. The power lines 50, the
suction line 52, and the expansion line 54 may be disposed within
the sleeve 48. The power lines 50 may include any cable used to
distribute electricity 56. The suction line 52 and the expansion
line 54 may be a system of elongated 5 tubes that may be used to
pass a coolant 58 between the local unit 34 and the remote unit 36.
The coolant 58 may be any agent that produces cooling, especially a
working fluid (liquid or gas) that relays heat through circulation.
Examples of the coolant 58 of FIG. 2A include air, ammonia, water,
carbon dioxide, the fluorinated hydrocarbon Freon.RTM., and the
high-pressure coolant chlorodifluoromethane R-22.
[0051] When disposed within the suction line 52, the coolant 58 may
be referred to as a chilled coolant 60 since the suction line 52
may transmit a relatively low temperature coolant 58 from the local
unit 34 to the remote unit 36. When disposed within the expansion
line 54, the coolant 58 may be referred to as a heated coolant 62
since the expansion line 54 may transmit a relatively high
temperature coolant 58 from the remote unit 36 to the local unit
34. To maintain the temperature of the chilled coolant 60, the
suction line 52 further may include insulation 64 disposed about an
exterior of suction line 52.
[0052] In operation, the chilled coolant 60 may pass through
evaporator coils 220 (FIG. 15) within the local unit 34 as air is
passed over the evaporator coils 220. A side effect of the chilled
coolant 60 passing through the local unit 34 as air is passed over
the evaporator coils 220 is that atmospheric moisture from the
passing air may condense on evaporator coils 220 as a condensate
66. The condensate 66 may collect in a pan 221 (FIG. 15) at a base
218 of the local unit 34. It is desirable to remove the condensate
66 from the pan 221 so that the condensate 66 does not spill out of
the local unit 34.
[0053] To aid in removing the condensate 66, the supply cable 38 of
FIG. 2A may further include a condensate line 68. The condensate 66
may be moved through the condensate line 68 by a condensate removal
pump 299 (FIG. 24). When the condensate removal pump 299 is located
in the remote unit 36 and is an air pump that pumps air 70, the
supply cable 38 may also include an air tube 72. The air tube 72
may include a filter to purify the air 70 prior to the air 70
entering the indoor area 28.
[0054] An advantage of the mini-split air conditioner 26 is that
the local unit 34 may be installed at a location that is remote
from the window 32. Moreover, the remote unit 36 may be installed
at a location that is remote from the window 32 so as to minimize
or completely eliminate the introduction of noise into the indoor
area 28 from the remote unit 36. Further, the mini-split air
conditioner 26 may include two or more of the local units 34 where
each local unit 34 may be distributed within the indoor area 28 as
well as coupled to the remote unit 36.
[0055] The mini-split air conditioner 26 of FIG. 2 may be installed
as follows. The remote unit 36 may be placed on a surface 74 in the
outdoor area 30. The supply cable 38 may be coupled to the remote
unit 36 and routed through the wall 22 to a location within the
indoor area 28. Part of the supply cable 38 is shown in phantom in
FIG. 2 to indicate that the supply cable 38 is routed on the
outdoor area 30 side of the wall 22. The supply cable 38 may also
be routed on the indoor area 28 side of wall 22. The supply cable
38 may be coupled to the local unit 34. The local unit 34 may then
be fixed to a position within the indoor area 28, such as on the
wall 22.
[0056] FIG. 3 illustrates a perspective view of the portable air
conditioner 80. Included with the portable air conditioner 80 may
be the supply cable 38 disposed between a local unit 82 and a
remote unit 84.
[0057] The local unit 82 may include the front grill 39, the
housing 42, a platform 86, casters 88, a plate 90, the first louver
40 (FIG. 2), a second louver 92 (FIG. 15), and a fan 94. While an
axial fan is illustrated at 94, those skilled in the art recognize
that many other type fans could be utilized, and that reference in
this description to an axial fan is for illustrative purposes only.
As in the split air conditioner 26 of FIG. 2, the front grill 39
may be disposed in or as part of the housing 42. The front grill 39
may include finger handles 95 to aid in removing the front grill 39
from and installing the front grill 39 into the housing 42.
[0058] The housing 42 may be disposed on the platform 86.
Alternatively, the platform 86 may be part of the housing 42. In
general, the platform 86 may include any horizontal surface raised
above the level of an adjacent area. In the embodiment shown, the
platform 86 may be raised above the level of an adjacent area by
the casters 88. Each caster 88 may include a small wheel on a
swivel. The swivel may be attached under a platform to make it
easier to move a platform and to transport a unit of the portable
air conditioner 80. The plate 90 may be used to display a company
logo.
[0059] In the view shown in FIG. 3, the second louver 92 has been
removed to reveal the fan 94. The fan 94 may define an axis of
rotation that is parallel to a horizontal flow of air drawn by the
fan 94. The fan 94 may aid in circulating air into the local unit
82 through the front grill 39 and out of the local unit 38 through
the first set of louvers 40 and the second set of louvers 92 (FIG.
15).
[0060] The remote unit 84 of FIG. 3 may include a first set of
louvers 41 (FIG. 28), a second set of louvers 44, the housing 46, a
first back grill 96, a second back grill 98, a platform 99, and the
casters 88. The second louver 44 may be coupled to the housing 46
as shown. Moreover, each of the first back grill 96 and the second
back grill 98 may be disposed in the housing 46 on the supply cable
38 side of the remote unit 84 to receive air that is external to
the remote unit 84 (as discussed in connection with FIG. 27 and
FIG. 28). The housing 46 may be disposed on the platform 99.
Alternatively, the platform 99 may be part of the housing 46. In
general, the platform 99 may include any horizontal surface raised
above the level of an adjacent area. In the embodiment shown, the
platform 99 may be raised above the level of an adjacent area by
the casters 88.
[0061] FIG. 4 illustrates a perspective view of the saddle air
conditioner 100. The saddle air conditioner 100 may include a local
unit 102, a remote unit 104, and a bridge 106. The local unit 102
and the remote unit 104 maybe similar to the local unit 34 and the
remote unit 36 of FIG. 2, respectively, or to the local unit 82 and
the remote unit 84 of FIG. 3, respectively.
[0062] The bridge 106 may include a low-profile, rectangular shaped
channel. Moreover, the bridge 106 may be coupled between the local
unit 102 and the remote unit 104 to provide a structure from which
the local unit 102 and the remote unit 104 may hang. The bridge 106
may also serve to channel between the local unit 102 and the remote
unit 104 at least one of the following: the power lines 50 (FIG.
2A), the suction line 52, the expansion line 54, the condensate
line 68, and the air tube 72.
[0063] The bridge 106 of FIG. 4 may include a plurality of
telescoping beams, such as two telescoping beams. In the embodiment
shown in FIG. 4, the bridge 106 includes a first beam 108 and a
second beam 110. The first beam 108 and the second beam 110 each
may be a telescoping beam.
[0064] FIG. 5 is a perspective view of the first beam 108 taken
along of line IVA-IVA of FIG. 4. The first beam 108 may include a
first or interior channel 111 and a second or exterior channel 112.
The interior channel 111 may include a base 114 coupled between a
first side 116 and a second side 118. The exterior channel 112 may
include a base 120 coupled between first side 122 and second side
124. The first side 122 of the exterior channel 112 may be coupled
to a first L-shaped bracket 126 whereas the second side 124 may be
coupled to a second L-shaped bracket 128, such that the second
L-shaped bracket 128 may oppose the first L-shaped bracket 126.
[0065] The interior channel 111 and the exterior channel 112 each
may be made from galvanized steel. In one embodiment, the material
thickness of at least one of the interior channel 111 and the
exterior channel 112 is less than or equal to one eighth of an inch
thick. In another embodiment, the exterior channel 112 is a 1-5/8
inch wide metal framing channel P-4100.
[0066] In assembly, a first end of the interior channel 111 may be
fixed to the remote unit 104, such as by welding or bolting, such
as with bolts 109 (FIG. 4). A first end of the exterior channel 112
may be fixed to the local unit 102 in a similar manner. A second
end of the exterior channel 112 may be disposed to abut the remote
unit 104 when the remote and local units are disposed in the
closest disposition end (not shown).
[0067] Included with the bridge 106 may be a cover 130. The cover
130 may include two overlapping sections that may be adapted to
move relative to one another over a predetermined distance without
separating from one another.
[0068] FIG. 6 illustrates a perspective view of the saddle air
conditioner 100 with the cover 130 removed. As shown, the bridge
106 may further include an interior tray 132 and an exterior tray
134. The interior tray 132 and the exterior tray 134 each may be
viewed as a channel.
[0069] The interior tray 132 may be coupled to the housing 46 of
the remote unit 104. For example, the interior tray 132 may be
coupled to the back and base of the housing 46 to form a Z-shaped
structure 133 similar to remote Z-bracket 200 of FIG. 14.
[0070] The exterior tray 134 of the local unit 102 similarly may
form a part of a Z-shaped structure with respect to the housing
42.
[0071] The interior tray 132 and the exterior tray 134 may have a
structure that permits the interior tray 132 to be disposed within
the exterior tray 134. In the embodiment shown, the interior tray
132 may include a base 136 disposed between a first lip 138 and a
second lip 140. The exterior tray 134 may include a base 146
disposed between the exterior channel of beam 108 and 110. The base
146 may define a length that may equal a length of the housing
42.
[0072] In one embodiment, the remote unit 104 may be about eighty
pounds (thirty six kilograms) and the local unit 102 maybe about
thirty pounds (14 kilograms).
[0073] To assemble the local unit 102 to the remote unit 104, the
interior channels 111 are inserted into channels 112 and secured by
hand screw fasteners 148 in slots 152 in channels 112. The power
lines 50 and line 52, 54 may be connected and the cover 130 placed
on the local unit 102 and remote unit 104 to form the saddle
conditioner 100. Thus the units 102 and 104 may be disposed a
predetermined distance from each other, the predetermined distance
may be the width of a windowsill.
[0074] FIG. 7 illustrates flexible tubing disposed within the
bridge 106. Flexible tubing (or pipeline) may include tubing that
can be installed in single long runs without the necessity of
regular joints either to extend the length of the tubing or to
change directions. In one embodiment, flexible tubing may be
disposed between the local unit 102 and the remote unit 104 to
provide passageways for electricity 56 (FIG. 2A), the chilled
coolant 60, the heated coolant 62, the condensate 66, and the air
70. For example, disposed within the bridge 106 may be at least one
of the power lines 50, the suction line 52, the expansion line 54,
and the condensate line 68. Each may employ flexible tubing which
may be accessible by removing the cover 130 (FIG. 5) from the
interior tray 132 and exterior tray 134 as shown in FIG. 7.
[0075] FIG. 8 illustrates a helical tubing 158. FIG. 9 illustrates
a serpentine tubing 168. FIG. 10 illustrates a roll tubing 180. The
helical tubing 158, the serpentine tubing 168, and the roll tubing
180 each may be viewed as a type of flexible tubing. Here, each of
the helical tubing 158, the serpentine tubing 168, and the roll
tubing 180 may be flexible through structural design or a
combination of structural design and selection of material. The
material of one of the helical tubing 158, the serpentine tubing
168, and the roll tubing 180 may include plastic, rubber, cloth,
metal, polyvinyl chloride (PVC), or wood.
[0076] The helical tubing 158 of FIG. 8 may be defined by a
three-dimensional curve disposed about an axis 160 so that an angle
of the curve to a plane disposed perpendicular to the axis 160 is
constant. The distance between the axis 160 and the center 162 of
the helical tubing 158 may define a radius 164. The radius 164 may
be constant or may vary over a length of the helical tubing 158. In
one embodiment, the radius 164 ranges from 0.1 to 0.4 inches. In
another embodiment, the radius 164 equals 0.25 inches. The helical
tubing 158 may extend in the directions of arrows 166 and may
include connectors (not shown) at each end.
[0077] The serpentine tubing 168 of FIG. 9 may be defined by a
two-dimensional curve that follows a sinuous path. The serpentine
tubing 168 may include curved pieces 170, straight sections 172, a
first coupler curve 174, and a second coupler curve 176. The curved
pieces 170 may be hollow tubes bent towards a C-Shape or U-Shape.
The straight sections 172, the first coupler curve 174, and the
second coupler curve 176 each may be hollow tubes. Moreover, the
first coupler curve 174 and the second coupler curve 176 may be
bent at an angle of greater than ninety degrees.
[0078] The straight sections 172 may couple the curved pieces 170,
the first coupler curve 174, and the second coupler curve 176 to
one another. The serpentine tubing 168 may extend in the direction
of arrows 178. Moreover, the serpentine tubing 168 may include
connectors (not shown) at each end and may be made of rigid
material.
[0079] Based on the various standard window constructions around
the world, it is important that the distance between the first
coupler curve 174 and the second coupler curve 176 be adapted to
expand or contract over a length of about ten inches (twenty five
centimeters). However, the distance between each curved piece 170
is limited to the length of the window 32. To provide the desired
flexibility over the width of the bridge 106 (FIG. 7) when
serpentine tubing 168 is made from rigid material and used in the
bridge 106, the serpentine tubing 168 includes at least two curved
pieces 170 as shown in FIG. 9. A construction of the serpentine
tubing 168 having a single curved piece 170 would be insufficient
to permit expansion and contraction over a ten-inch length.
[0080] The roll tubing 180 of FIG. 10 may be defined by windings
182. Each winding 182 may define a perpendicular axis that is
parallel to the axes of the other windings 182. Each of the
windings 182 may overlap an adjacent winding 182 or be overlapped
by an adjacent winding 182. In one embodiment, an overlap of
adjacent windings 188 may define a height that extends
perpendicularly from the view of FIG. 10 to a range of 0.25 to 0.80
inches. The roll tubing 180 may extend in the direction of arrows
184. Moreover, the roll tubing 180 may include connectors (not
shown) at each end and may be made of rigid material. To provide
the desired flexibility over the width of the bridge 106 when the
roll tubing 180 is made from rigid material, the roll tubing 180
includes at least two windings 182 as shown in FIG. 9.
[0081] The helical tubing 158 provides good flexing action whereas
the serpentine tubing 168 and the roll tubing 180 provide low
profile advantages. At least one of the helical tubing 158, the
serpentine tubing 168, and the roll tubing 180 may be used for at
least one of the power lines 50 (FIG. 2A), the suction line 52, the
expansion line 54, the condensate line 68, and the air tube 72. In
one embodiment, the serpentine tubing 168 may be made from copper
and used for the suction line 52. This may be seen in FIG. 7.
Moreover, the roll tubing 180 may be used for the expansion line
54, where the expansion line 54 may be long and slender with a very
small internal diameter, much like a capillary vessel. The helical
tubing 158 may be used for the air tube 72. Further, a meandering
line may be used for the power lines 50 and the condensate line 68
as seen in FIG. 7.
[0082] FIG. 11 illustrates an installation of the saddle air
conditioner 100. The saddle air conditioner 100 may be installed
into the wall 22 having the window 32 to give a consumer full
access to the window 32. Giving a consumer full access to the
window 32 eliminates the need to remove the saddle air conditioner
100 from the window 32 during winter. This also permits a consumer
to place decorations such as flowerpots and pictures on the top of
the local unit 102 without concern that the decorations will need
to be relocated during winter.
[0083] The window 32 may include an upper sash 186 and a lower sash
188. The lower sash 188 may include a sash frame 190 and a glass
192 disposed within the sash frame 190. The window 32 further may
include a windowsill 194 having a bottom rail 196.
[0084] To install the saddle air conditioner 100 into the window
32, the lower sash 188 may be raised towards the position of the
upper sash 186. From a position within the indoor area 28, the
saddle air conditioner 100 may be raised and extended so that the
remote unit 104 may be positioned within the outdoor area 30 and
the local unit may be positioned within the indoor area 28. The
saddle air conditioner 100 may then be lowered so that the bridge
106 contacts the bottom rail 196 of the windowsill 194.
[0085] To provide a seal between the indoor area 28 and the outdoor
area 30, the saddle air conditioner 100 may further include a gap
filler 198. The gap filler 198 may be a preformed foam or
insulating material. Moreover, the gap filler 198 may include one
or more cutouts 199 and may be made of an insulating material, such
as urethane foam. FIG. 12 illustrates the gap filler 198 having one
cutout 199. The arrangement of the gap filler 198 in FIG. 12 may be
used for the saddle air conditioner 100 as seen in FIG. 5. FIG. 13
illustrates the gap filler 198 having two cutouts 199. The
arrangement of the gap filler 198 of FIG. 13 may be used for the
saddle air conditioner 100 of FIG. 4. The gap filler 198 may be
disposed over the bridge 106 and the bottom rail 196. With the gap
filler 198 in position, the sash frame 190 of the lower sash 188
may be closed onto the gap filler 198.
[0086] Alternatively, the sash frame 190 may be designed with two
notches that fit around the exterior of the beam 106 and the first
beam 108 of FIG. 4. This may maximize the direct contact between
the lower sash 188 and the bottom rail 196 and further provide
access to the window 32 to a consumer.
[0087] As noted above, the interior tray 132 may be coupled to a
back and base of the housing 46 to form a Z-shaped structure. FIG.
14 illustrates the saddle air conditioner 100 with the exterior
tray 134 and the majority of the remote unit 104 removed to reveal
a Z-bracket 200. The Z-bracket 200 may include a back 202 coupled
between the interior tray 132 and a base 204 to form a Z-shaped
structure. A single sheet of metal may define the interior tray
132, the back 202, and the base 204.
[0088] The back 202 may form a punch out 208. The interior tray 132
may include indents 210. The base 204 may include a support hole
212 and a sump 213. The tab 206 and the support hole 212 may aid in
supporting parts disposed on the base 204 (such as a brace 297 of
FIG. 24). The indents 210 may provide a raised portion into which
an installation bracket 300 (FIG. 25) may be disposed. The sump 213
may serve as a repository for the waste condensate 66 as discussed
more fully in connection with FIG. 24.
[0089] As seen in FIG. 14, the housing 42 of the local unit 102 may
include a center housing 214 disposed between a top housing 216 and
a base 218. The front grill 39 may be located within the center
housing 214 by employing the finger handles 95.
[0090] FIG. 15 is an exploded view of the local unit 102 of FIG.
14. As seen in FIG. 15, residing behind the front grill 39 may be
the evaporator coils 220. As noted above, atmospheric moisture from
air passing over the evaporator coils 220 may condense on the
evaporator coils 220 as the condensate 66 (FIG. 2A). To collect the
condensate 66, the local unit 102 of FIG. 15 may further include a
trough or pan 221. The pan 221 may be fixed to the base 218 at a
location that is below the evaporator coils 220. The pan 221 may
include an angled bottom that meets at a midpoint of the pan 221.
The local unit 102 may further include a back plate 223 to complete
the housing 42.
[0091] The evaporator coils 220 may be connected to the expansion
line 54 (FIG. 2A) through an expansion device or valve (not shown).
In the process of the high pressure coolant 62 passing though the
expansion device, the high pressure coolant 62 may go through a
pressure drop to become the cold, low-pressure chilled coolant 60
in a vapor/liquid phase. In this regard, the evaporator coils 220
of the local unit 102 may be a set of coils that allow the chilled
coolant 60 to absorb heat and cool down the air inside the indoor
area 28. Thus, the local unit 102 may be referred to as an
evaporator unit where the evaporator coils 220 may serve as part of
an evaporator heat exchanger system. In one embodiment, the
evaporator coils 220 are flat coils.
[0092] Behind the evaporator coils 220 may be an orifice 222.
Behind the orifice 222 may be a fan deflector 224. Circumscribed by
the fan deflector 224 may be a fan ring 226 disposed against the
fan blades 227 of the fan 94. Air inside the indoor area 28 may be
drawn through the evaporator coils 220 by the fan 94 so as to be
cooled. The bearings 228 may permit a shaft 229 to rotate the fan
94 without the shaft 229 rotating the fan deflector 224. The
orifice 222 may aid in directing this now cooled air into the fan
94. The fan 94 may centrifugally expel the cooled air into the fan
deflector 224 as directed by the fan blades 227. The fan deflector
224 may then direct the cooled air through the first louver 40 and
the second louver 92 of the center housing 214 into the indoor area
28.
[0093] A motor may drive the fan 94. Conventionally, a motor is
located directly behind a fan in a saddle air conditioner to
provide a direct drive of a fan. Moreover, conventional high-speed
operations may occur at 1100 revolutions per minute (RPM). To
reduce the level of noise introduced into the indoor area 28 from
the operations of fan 94, the fan 94 may be driven at low speeds,
such as 500 to 700 RPM. Although it is possible to accomplish this
with a low speed, direct drive motor, low speed motors are
relatively more expensive when high efficiency is needed.
[0094] To drive the fan 94 at low speeds, the local unit 103 of the
saddle air conditioner 100 may further include a fan motor system
230. The fan motor system 230 may be simply an efficient low speed
motor. Also, system 230 may be, as illustrated as an indirect
drive, pulley operated, fan speed reduction system. The fan motor
system 230 may include a motor 232, a first pulley wheel 234, a
second pulley wheel 236, and a pulley belt 238. The motor 232 may
be coupled to the base 218 through a motor bracket 240. Between the
motor bracket 240 and the motor 232 may be a cushion ring 242. The
cushion ring 242 may work to absorb vibrations of the motor 232 and
to prevent these vibrations from transmitting to the base 218 of
housing 42.
[0095] FIG. 16 is a front view of the local unit 102. FIG. 16A is a
sectional view of the local unit 102 taken along line XVIA-XVIA of
FIG. 16. FIG. 16B is a sectional view of the local unit 102 taken
along line XVIB-XVIB of FIG. 16. FIG. 17 is a top view of the local
unit 102. FIG. 16A and FIG. 16B each illustrate aspects of the fan
motor system 230.
[0096] As seen in FIG. 16A, the shaft 229 may be disposed in the
center of the first pulley wheel 234. From FIG. 16B, it may be seen
that a shaft 244 of the motor 232 may be disposed in the center of
the second pulley wheel 236. The shaft 229 may define an axis that
is parallel to, but remote from, an axis of the shaft 244. The
independence of the motor 232 from the remote unit 104 works to
allow the motor 232 to handle a greater pressure drop, such as may
be caused by the use of a filter. In this embodiment, the local
unit 102 may include a filter 250 disposed between the front grill
39 and the evaporator coils 220 to aid in purifying the air from
the indoor area 28. The filter 250 may be a high performance air
filter that adds an air-purifying feature to the cooling
capabilities of the saddle air conditioner 100.
[0097] FIG. 18 illustrates an exploded perspective view of the fan
motor system 230. As seen, the first pulley wheel 234 may be
coupled to the shaft 229 and the second pulley wheel 236 may be
coupled to the shaft 244 of the motor 232. The pulley belt 238 may
be coupled between the first pulley wheel 234 and the second pulley
wheel 236. The pulley belt 238 may be any power-transmitting device
adapted to rotate over a path that leads back onto itself. The
first pulley wheel 234 may define a diameter that is larger than a
diameter of the second pulley wheel 236.
[0098] The motor 232 may include a plurality of poles where the
number of poles is less than six. For example, the motor 232 may be
a four pole permanent split capacitor fan motor having an operating
speed of around 1500 revolutions per minute (RPMs) at an efficiency
of 50 to 90 percent. Moreover, the motor 232 may be a two-pole
motor. The motor 232 may also be a C-frame motor having an
operating speed in the range of 2400 to 3500 RPMs at a maximum
efficiency of 20-30%. The first pulley wheel 234 and the second
pulley wheel 236 may define a diameter relationship that reduces
the operating speed of the motor 232 at shaft 229 to a range of 500
to 700 RPMs at an efficiency of higher than 85%. In one embodiment,
the ratio of the diameter of the first pulley wheel 234 to the
diameter of the second pulley wheel 236 may be in the range of
about 3:2 to 7:1 with an efficiency of 95% to 98%.
[0099] A low power transmission loss between the shaft 244 and the
shaft 229 may work to lower the cost of the local unit 102 while
maintaining the desired fan output speed. Moreover, the separation
of motor 232 from the shaft 229 allows for better spatial
management of the motor and the fan. The separation of motor 232
from the shaft 229 also permits reduction in the weight of a unit
of the saddle air conditioner 100 due to the reduction in the
number of poles. Noise may also be reduced due to isolating the
motor 232 from the motor bracket 240 by the cushion ring 242.
[0100] The above embodiments are described in connection with the
fan 94. Recall that the fan 94 may define an axis of rotation that
is parallel to a horizontal flow of air drawn by the fan 94. In an
alternate embodiment, the split air conditioner 10 may employ twin
cross flow blower wheels.
[0101] FIG. 19 illustrates a first blower wheel 246 and a second
blower wheel 248 disposed in on unit of the split air conditioner
10. The unit illustrated in FIG. 19 is the local unit 102. FIG. 20
illustrates the first blower wheel 246 and the second blower wheel
248 disposed behind the evaporator coil 220. The first blower wheel
246 and the blower wheel 248 may work to draw air through the
evaporator coil 220.
[0102] The second blower wheel 248 may be of similar structure as
the first blower wheel 246. As seen in FIG. 19, the first blower
wheel 246 may define the vertical axis 250 about which the first
blower wheel 246 may rotate. Employing two vertically disposed
blower wheels may permit the first blower wheel 246 and the second
blower wheel 248 to define a length that is shorter than a single,
horizontally disposed blower wheel, such as seen in U.S. Pat. No.
5,335,721. A shorter blower wheel is less likely to vibrate and
generate noise from this vibration.
[0103] Disposed around the vertical axis 250 may be the blade sets
252. Each blade set 252 may include the blades 254 radially
distributed about the vertical axis 250 and divided by the blade
ring 256. In one embodiment, the first blower wheel 246 includes
four blade sets 252. In another embodiment, the blades 254 are
curved.
[0104] In this embodiment, the local unit 102 may further include
the sleeve bearings 258, the upper blower support 260, the bearing
supports 262, the shroud 264, the blower cutoff 266, and the blower
cutoff 268. The sleeve bearings 258 may be any device that permits
a blower wheel to rotate freely about the vertical axis 250. The
sleeve bearing 258 may be coupled to a shaft (not shown) of the
first blower wheel 246. The upper blower support 260 may be an
L-shaped bracket secured to the back plate 223 at a location above
the first blower wheel 246. The bearing supports 262 may be a disc
having a ring extending inward to a raised dome, where the dome
couples each sleeve bearing 258 to the upper blower support 260
through the ring. The dome may be adapted to permit a blower wheel
to rotate below the raised dome.
[0105] The shroud 264 may be a continuous formed sheet that aids in
channeling air from the front grill 39 to the first louver 40 and
the second louver 92. FIG. 21 is a perspective view of the local
unit 102 with the first blower wheel 246 and the second blower
wheel 248 removed to reveal the shroud 264. The shroud 264 may
include the wall 270, the first curved portion 272, the first
channel 274, the second curved portion 276, and the second channel
278.
[0106] The wall 270 may extend as part of the shroud 264 from a
point adjacent to the evaporator coils 220 towards the back plate
223 at a midpoint of the evaporator coils 220. In this arrangement,
the wall 270 may serve to evenly divide and channel an inlet
measure of air between the first blower wheel 246 and the second
blower wheel 248. The first curved portion 272 may be coupled
between the wall 270 and the first channel 274. Moreover, the
second curved portion 276 may be coupled between the wall 270 and
the second channel 278.
[0107] An inlet measure of air that is guided towards the first
blower wheel 246 may encounter the first curved portion 272. The
shape of the first curved portion 272 may cause the measure of air
to change directions towards the first blower wheel 246. In one
embodiment, the first curved portion 272 defines a perimeter that
is one quarter of a circle.
[0108] The first channel 274 may be disposed about the first blower
wheel 246 from the first curved portion 272 to a location that is
adjacent to the first louver 40 (FIG. 2). As the first blower wheel
246 rotates within the first channel 274, air may be moved from the
first curved portion 272 to the first louver 40 as guided by the
first channel 274. On reaching the first louver 40, the air may
encounter the blower cutoff 280. The blower cutoff 280 may have a
first edge that extends to a location that is adjacent to the first
blower wheel 246 and a second edge that extends to a location that
is adjacent to the first louver 40. This arrangement of the blower
cutoff 246 may strip air from the first blower wheel 246 and guide
the air towards the first louver 40. The second curved portion 276,
the second channel 278, and the blower cutoff 282 may define a
structure and arrangement that aids the second blower wheel 248 in
moving a measure of air from the evaporator coil 220 to the second
louver 92. The structure and arrangement of the second curved
portion 276, the second channel 278, and the blower cutoff 282 may
be similar to that of the first curved portion 272 and the first
channel 274.
[0109] FIG. 22 is a perspective view of the local unit 102 with the
shroud 264 removed to reveal the first motor 284 and the second
motor 286. Each first motor 284 and 286 may be coupled to the wheel
motor shafts 288 of FIG. 21. The first motor 284 and second motor
286 may be independently operated motors that work towards
providing independent operations for each of the first blower wheel
246 and the second blower wheel 248.
[0110] As an alternative to the first motor 284 and the second
motor 286, the first blower wheel 246 and the second blower wheel
248 may employ an indirect drive, pulley operated, fan speed
reduction system similar to the fan motor system 230 of FIG. 18.
FIG. 22A illustrates a blower wheel motor system 289. Each wheel
motor shaft 288 may be coupled to a first pulley wheel 234. The
pulley belts 238 may extend from each of the first pulley wheel 234
to one of two the second pulley wheels 236 mounted to the shaft 244
of the motor 232. The motor 232 maybe disposed below the wall 270
(FIG. 21) of the shroud 264 to provide a balanced operation.
[0111] As has been shown in the embodiments of FIGS. 15, 18, and
19, the local unit is capable of being a stand alone unit. Thus,
referring for example, to FIG. 15, a HEPA filter 222 may be
substituted for the evaporator 220, and the local unit may be
utilized as a stand alone air purifier. Thus, the local unit
configuration facilitates the unit functioning as the basis for a
saddle mount air conditioner, a split air conditioner, and an air
purifier. In each case, the local unit mounts in the save vertical
orientation.
[0112] FIG. 23 is a perspective view of the saddle air conditioner
100 with the parts removed to reveal details of a remote unit 104.
As shown in the view of FIG. 23, the remote unit 104 may include a
conventional condenser tubes 290. The condenser 290 may include set
of heat exchanging pipes coupled at a first end to the suction line
52 (FIG. 2A) through the compressor 292 and at a second end to the
expansion line 54 (FIG. 2A) through an expansion valve (not shown).
The condenser 290 may be disposed about two radii to present a
U-shaped configuration.
[0113] FIG. 24 is a detailed view of the remote unit 104 with the
condenser tubes 290 removed. The remote unit 104 further may
include the fan orifice 294 disposed about the condenser fan 296,
the brace 297, and the condensate sump 298. In conventional split
air conditioners, the condensate is discharged to the ground.
However, this causes a major inconvenience and wastes a resource
that may be used for other purposes. For example, by discharging
the condensate 66 (FIG. 2A) from the condensate line 68 into the
condensate sump 298, the condenser fan 296 may draw the condensate
66 up with the aid of a slinger ring (not shown) and splash the
condensate 66 onto the coils of the condenser tubes 290. Here, the
dispensed condensate 66 may draw heat away from the coils of the
condenser tubes 290 through evaporation. This, in turn, increases
the efficiency of the saddle air conditioner 100 by as much as
seven percent and works to prevent blemishing of a building facade
(e.g., wall 22) by water stains.
[0114] The remote unit 104 may further include the condensate
removal pump 299 disposed within the remote unit 104. The
condensate removal pump 299 may be used to remove the condensate 66
(FIG. 2A) from the pan 221 (FIG. 21). In one embodiment, the
condensate removal pump 299 is a water pump. In another embodiment,
the condensate removal pump 299 is an air assisted condensate
pumping system. Locating the condensate removal pump 299 in the
remote unit 104 works towards reducing the amount of indoor noise
produced by the split air conditioner 10.
[0115] FIG. 25 illustrates an installation bracket 300 of the
invention. The installation bracket 300 may simplify installation
of the saddle air conditioner 100 into the window 32 (FIG. 11). The
installation of the saddle air conditioner 100 into the window 32
may be simplified by the installation bracket 300 in that the
installation bracket 300 permits the saddle air conditioner 100 to
be installed completely from the indoor area 28. A consumer need
not reach out of the window 32 for installation or adjustment.
Additionally, the installation bracket 300 may keep the remote unit
104 away from the wall 22. Keeping the remote unit 104 away from
the wall 22 works to permit air to enter from the back of the
remote unit 104 so as to minimize or eliminate the need to draw air
into the remote unit 104 from the top of the remote unit 104.
[0116] The installation bracket 300 may include the local frame 302
and the remote frame 304. The local frame 302 may be coupled to the
remote frame 304 as detailed below. Moreover, the local frame 302
maybe used in relation to the local unit 102 and the remote frame
304 may be used in relation to the remote unit 104. Each of the
local frame 302 and the remote frame 304 may be made from a light
weight sheet metal, plastic, or a combination thereof.
[0117] The local frame 302 may include a brace 306, a first rib
308, a first leg 310, and a second leg 312. The brace 306 may
extend between the first leg 310 and the second leg 312 at a lower
end of the first leg 310 and the second leg 312. The first rib 308
may extend between the first leg 310 and the second leg 312 at a
midpoint of the first leg 310 and the second leg 312 to retain the
first leg 310 at a fixed distance from the second leg 312.
[0118] A top surface of the local frame 302 may include the second
rib 310 and the local crossbar 312 disposed between a first bar 314
and a second bar 316. At a midpoint of the first bar 314 and the
second bar 316, the second rib 310 may retain the first bar 314 at
a fixed distance from the second bar 316. The first bar 314 maybe
coupled to the first leg 310 at an angle of ninety degrees and the
second bar 316 may be coupled to the second leg 312 at an angle of
ninety degrees. The local crossbar 312 may be disposed between the
first bar 314 and the second bar 316 at a distal location from the
first leg 310 and the second leg 312.
[0119] The local frame 302 further may include a first spacer 318
and a second spacer 320. Each of the first spacer 318 and the
second spacer 320 may include a shaft 322 disposed between a knob
324 and a pad 326. The shaft 322 may include the external threads.
The knob 324 may be a turning handle. The pad 326 may include
rubber. To aid in assembling the local frame 302 into the remote
frame 304, the first bar 314 may include a first slot 328 and the
second bar 316 may include a second slot 330.
[0120] The remote frame 304 may include a brace 332, a first rib
334, a first leg 336, and a second leg 338. The first leg 336 and
the second leg 338 each may have a first foot 337 and a second foot
339, respectively, extending ninety degrees from a lower portion
towards the local frame 302. The brace 332 may extend between and
ninety degrees up from the first foot 337 and the second foot 339.
The first rib 334 may extend between the first leg 336 and the
second leg 338 at a midpoint of the first leg 336 and the second
leg 338 to retain the first leg 336 at a fixed distance from the
second leg 338.
[0121] A top surface of the remote frame 304 may include a second
rib 340, a remote crossbar 342, and a third rib 343 disposed
between a first bar 344 and a second bar 346. At a midpoint of the
first bar 344 and the second bar 346, the second rib 340 may retain
the first bar 344 at a fixed distance from the second bar 346. The
first bar 344 may be coupled to the first leg 336. Moreover, the
second bar 346 may be coupled to the second leg 338. The remote
crossbar 342 may be disposed between the first bar 344 and the
second bar 346 at a distal location from the third rib 343.
[0122] The arrangements of the brace 332, the first rib 334, and
the third rib 343 with respect to the first leg 336 and the second
leg 338 define openings 347. The height of the brace 332 and the
first rib 334 may be minimized to maximize the size of the openings
347. In one embodiment, the collective height of the openings 348
accounts for at least 90% of the overall distance the first foot
337 to the third rib 343.
[0123] The remote frame 304 further may include a first spacer 348
and a second spacer 350. Each of the first spacer 348 and the
second spacer 350 may include the shaft 322 disposed between the
knob 324 and the pad 326. To aid in assembling the remote frame 304
into the local frame 302, the first bar 344 may include a first
slot 352 (not shown) and the second bar 346 may include a second
slot 354 (not shown). The installation bracket 300 may further
include a connector such as the bolt and wing nut assembly 356.
[0124] To assemble the local frame 302 and the remote frame 304
together, the first slot 328 may be aligned with the first slot 352
to form a first slot group and the second slot 330 may be aligned
with the second slot 354 to form a second slot group. At least one
bolt and wing nut assembly 356 may be loosely fit into each slot
group. When assembled, an upper surface of the installation bracket
300 may define the platform 358.
[0125] FIG. 26 illustrates the installation bracket 300 disposed
over the bottom rail 196 (FIG. 11) of the wall 22. In this
arrangement, the platform 358 may span a width of the bottom rail
196. With the installation bracket 300 disposed over the bottom
rail 196, the local frame 302 and the remote frame 304 may be
pushed towards one another and each bolt and wing nut assembly 356
tightened. To maintain the remote frame 304 at distance 360 from
the wall 22, each knob 324 of first spacer 348 and second spacer
350 may be turned until each pad 326 engages an exterior surface of
the wall 22. The first spacer 318 and the second spacer 320 may
similarly be tightened.
[0126] The extent of space between a plane formed by the first leg
336 and the second leg 338 and the wall 22 may define distance 360.
The extent of space between the brace 332 and the wall 22 may
define distance 361. The distance 361 is less than the distance
360. In one embodiment, the distance between the brace 332 and the
wall 22 (distance 361) is at least fifty to seventy percent of the
distance between the first leg 336 and the wall 22 (distance
360).
[0127] As noted above, the structural arrangement of the remote
frame 304 may include the first foot 337 and the second foot 339,
each extending at ninety degrees from an associated leg towards the
local frame 302. The first foot 337 and the second foot 339 may
serve to bring the brace 332 to a position that is adjacent to the
wall 22 at distance 361.
[0128] Bringing the brace 332 to a position that is adjacent to the
wall 22 provides a number of advantages. For example, bringing the
brace 332 to a position that is adjacent to the wall 22 minimizes
the number of times knob 324 must be turned for the pads 326 to
engage the exterior surface of the wall 22. This reduces the time
it takes to position the installation bracket 300. As another
example, bringing the brace 332 to a position that is adjacent to
the wall 22 moves the forces experienced at the pads 326 closer to
the brace 332. This permits using the smaller and cheaper shafts
322 while providing a desired stability.
[0129] FIG. 27 illustrates the saddle air conditioner 100 disposed
over the installation frame 300. The remote unit 104 of the saddle
air conditioner 100 may be compact in width. For example, in one
embodiment, the distance between the wall 22 and a distal part of
front grill 43 is less than or equal to 9.75 inches. FIG. 28
illustrates the air path 362 with respect to the remote unit
104.
[0130] As seen in FIG. 27, the back 202 (FIG. 14) of the remote
unit 104 may be retained at the distance 360 from the wall 22 by
the installation bracket 300. The retention of the remote unit 104
from the wall 22 at the distance 360 may permit air to travel along
air path 362 (FIG. 28) to the back of the remote unit 104 and enter
the first back grill 96 and the second back grill 98. The entry of
air into the first back grill 96 and the second back grill 98 may
be in addition to air entering the first louver 41 and the second
louver 44. Drawing air into the remote unit 104 from the back 202
and the sides of the remote unit 104 works towards eliminating the
need to draw air from the top of the remote unit 104. In turn, not
drawing air from the top of the remote unit 104 works towards
preventing the noise from the condenser fan 296 from propagating to
the indoor area 28.
[0131] The exemplary embodiments described herein are provided
merely to illustrate the principles of the invention and should not
be construed as limiting the scope of the subject matter of the
terms of the claimed invention. The specification and drawings are,
accordingly, to be regarded in an illustrative rather than a
restrictive sense. Moreover, the principles of the invention may be
applied to achieve the advantages described herein and to achieve
other advantages or to satisfy other objectives, as well.
* * * * *