U.S. patent application number 11/895381 was filed with the patent office on 2008-02-28 for air conditioning unit support pan.
Invention is credited to James H. Kyle, Michael G. Patrick.
Application Number | 20080047289 11/895381 |
Document ID | / |
Family ID | 39112083 |
Filed Date | 2008-02-28 |
United States Patent
Application |
20080047289 |
Kind Code |
A1 |
Patrick; Michael G. ; et
al. |
February 28, 2008 |
Air conditioning unit support pan
Abstract
A mounting and collection pan for an air conditioning unit
including a bottom portion having a perimeter and a first flow
surface, a sidewall extending upwardly from the perimeter and a
first portal arranged in the sidewall. The air conditioning unit is
secured to the bottom portion and the first flow surface is angled
to direct a liquid condensate collected from the air conditioning
unit to the first portal via gravity. The bottom portion may
further include a first substantially horizontal mounting surface
having a first means for securing the air conditioner unit thereto
and is elevationally higher than the first flow surface.
Inventors: |
Patrick; Michael G.;
(Clearwater, FL) ; Kyle; James H.; (Keene,
NH) |
Correspondence
Address: |
SIMPSON & SIMPSON, PLLC
5555 MAIN STREET
WILLIAMSVILLE
NY
14221-5406
US
|
Family ID: |
39112083 |
Appl. No.: |
11/895381 |
Filed: |
August 24, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60840197 |
Aug 25, 2006 |
|
|
|
Current U.S.
Class: |
62/285 |
Current CPC
Class: |
F24F 13/32 20130101;
F24F 13/222 20130101; B63J 2/04 20130101; Y02T 70/72 20130101; Y02T
70/00 20130101 |
Class at
Publication: |
62/285 |
International
Class: |
F25D 21/14 20060101
F25D021/14 |
Claims
1. A mounting and collection pan for an air conditioning unit
comprising: a bottom portion having a perimeter, a first flow
surface and a first substantially horizontal mounting surface; a
sidewall extending upwardly from said perimeter; and, a first
portal arranged in said sidewall, wherein said first substantially
horizontal mounting surface comprises a first means for securing
said air conditioning unit thereto and elevationally higher than
said first flow surface and said first flow surface angled to
direct a liquid condensate collected from said air conditioning
unit to said first portal via gravity.
2. The mounting and collection pan as recited in claim 1 wherein
said sidewall extends substantially perpendicular from said bottom
portion.
3. The mounting and collection pan as recited in claim 1 wherein
said sidewall includes a second portal and said first flow surface
angled to direct said liquid condensate to said first and second
portals.
4. The mounting and collection pan as recited in claim 1 further
comprising: a trough integral to said bottom portion having first
and second ends proximate said sidewall, wherein said trough is
elevationally lower than said first flow surface, said first flow
surface is angled to direct said liquid condensate to said trough,
and said trough directs said liquid condensate to said first
portal.
5. The mounting and collection pan as recited in claim 4 wherein
said bottom portion further comprises a second flow surface angled
to direct said liquid condensate to said trough.
6. The mounting and collection pan as recited in claim 4 wherein
said trough extends substantially along a centerline of said
pan.
7. The mounting and collection pan as recited in claim 4 wherein
said first and second ends are elevationally lower than said trough
and one of said first and second ends is proximate said first
portal.
8. The mounting and collection pan as recited in claim 4 further
comprising: a second portal arranged in said sidewall, wherein said
trough directs said liquid condensate to said first and second
portals.
9. The mounting and collection pan as recited in claim 8 wherein
said first and second ends are elevationally lower than said trough
and proximate said first and second portals, respectively.
10. The mounting and collection pan as recited in claim 1 wherein
said first means for securing said air conditioning unit includes
at least one opening for receiving bolts.
11. The mounting and collection pan as recited in claim 1 wherein
said bottom portion further comprises a second mounting surface
substantially coplanar with said first mounting surface, said
second mounting surface comprising a second means for securing said
air conditioning unit thereto.
12. The mounting and collection pan as recited in claim 11 wherein
said second means for securing said air conditioning unit includes
at least one opening for receiving bolts.
13. The mounting and collection pan as recited in claim 1 further
comprising: a flange comprising means for securing said pan to a
substructure, wherein said flange extends substantially
perpendicular from said sidewall on an edge of said sidewall distal
from said perimeter.
14. The mounting and collection pan as recited in claim 13 wherein
said means for securing said pan to said substructure includes a
plurality of openings through said flange, each of said plurality
of openings arranged for receiving a bolt therethrough, said bolt
extending into said substructure.
15. The mounting and collection pan as recited in claim 14 further
comprising: a plurality of bushings, wherein each of said plurality
of bushings is positioned in one of said plurality of openings and
arranged for receiving said bolt therethrough.
16. The mounting and collection pan as recited in claim 15 wherein
each of said plurality of bushings comprises a vertical surface and
a horizontal surface, said vertical surface arranged to dampen a
horizontal vibration of said pan and said horizontal surface
arranged to dampen a vertical vibration of said pan.
17. The mounting and collection pan as recited in claim 1 further
comprising: a first rail and a second rail fixedly secured to a
lower surface of said bottom portion and arranged to separate said
pan from a substructure.
18. The mounting and collection pan as recited in claim 17 wherein
said first and second rails are constructed from an elastomer.
19. A mounting and collection pan for an air conditioning unit
comprising: a bottom portion having a perimeter and a first flow
surface; a sidewall extending upwardly from said perimeter; and, a
first portal arranged in said sidewall, wherein said air
conditioning unit is secured to said bottom portion and said first
flow surface angled to direct a liquid condensate collected from
said air conditioning unit to said first portal via gravity.
20. The mounting and collection pan as recited in claim 19 wherein
said bottom portion further comprises a first substantially
horizontal mounting surface, said first substantially horizontal
mounting surface comprises a first means for securing said air
conditioner unit thereto and elevationally higher than said first
flow surface.
21. A mounting and collection pan for an air conditioning unit
comprising: a bottom portion having a perimeter, a first flow
surface and a first substantially horizontal mounting surface; a
sidewall extending upwardly from said perimeter; and, a first
portal arranged in said sidewall and elevationally lower than said
first flow surface, wherein said first substantially horizontal
mounting surface comprises a first means for securing said air
conditioning unit thereto and elevationally higher than said first
flow surface and said first flow surface angled to direct a liquid
condensate collected from said air conditioning unit to said first
portal via gravity.
22. An air conditioning unit comprising: a blower; an evaporator; a
condenser; a compressor, said compressor arranged in fluid
communication said evaporator and said condenser, said evaporator
arranged in fluid communication with said condenser and said blower
arranged to exchange a volume of air over said evaporator; and, a
mounting and collection pan comprising: a bottom portion having a
perimeter, a first flow surface and a first substantially
horizontal mounting surface; a sidewall extending upwardly from
said perimeter; a first portal arranged in said sidewall, wherein
said first substantially horizontal mounting surface comprises a
first means for securing at least one of said blower, said
evaporator, said condenser and said compressor thereto and
elevationally higher than said first flow surface and said first
flow surface angled to direct a liquid condensate collected from
said blower, said evaporator, said condenser or said compressor to
said first portal via gravity.
23. An air conditioning unit comprising: a blower; an evaporator; a
condenser; a compressor, said compressor arranged in fluid
communication said evaporator and said condenser, said evaporator
arranged in fluid communication with said condenser and said blower
arranged to exchange a volume of air over said evaporator; and, a
mounting and collection pan comprising: a bottom portion having a
perimeter, a first flow surface and a first substantially
horizontal mounting surface; a sidewall extending upwardly from
said perimeter; a first rail and a second rail fixedly secured to a
lower surface of said bottom portion and arranged to separate said
pan from a substructure; and, a first portal arranged in said
sidewall and elevationally lower than said first flow surface,
wherein said first substantially horizontal mounting surface
comprises a first means for securing at least one of said blower,
said evaporator, said condenser and said compressor thereto and
elevationally higher than said first flow surface and said first
flow surface angled to direct a liquid condensate collected from
said blower, said evaporator, said condenser or said compressor to
said first portal via gravity.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit under 35 U.S.C.
.sctn.119(e) of U.S. Provisional Application No. 60/840,197, filed
Aug. 25, 2006, which application is incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to air conditioning
units. Particularly, it relates to condensation collection pans
that support air conditioning units. More specifically, it relates
to pans of this type used for marine air conditioning units.
BACKGROUND OF THE INVENTION
[0003] Air conditioning (AC) units generally include four principle
components: a compressor; an evaporator; a condenser; and, a
blower. These components may exist in a single, self-contained unit
or, in the alternative, may exist as two units working together,
wherein a first unit includes the compressor and condenser and a
second unit includes the evaporator and blower. This configuration
of two units working together is generally referred to as a split
system.
[0004] Marine AC units, i.e., those used aboard nautical vessels,
are generally single, self-contained units, particularly when used
aboard vessels less than approximately forty-five feet (45 ft.) in
length. Roughly, eighty percent (80%) of the recreational marine
market uses this type of AC unit, as it is inexpensive to build and
easy to install. The units are usually mounted in close proximity
to passengers of the vessel, for example, in a storage area of the
living quarters, or under a berth, bunk, or seat, as these areas
have the requisite space to house such a unit. They are not
normally located in the engine room, because they tend not to be
explosion-proof or ignition-proof, which makes them unsafe for
mounting in the engine room. Also, AC units require a significant
amount of energy to operate, and placing the unit close to the
location of the air discharge is more energy efficient. Since the
location of the air discharge is distant from the engine room, it
follows that the AC unit should also be distant from the engine
room.
[0005] Marine AC units are often secured to and supported by a pan,
which provides a means for collecting condensate produced by the
unit. Since the pan must be strong enough to support the AC unit
when it is shipped and when it is lowered into position, it is
generally made of a sturdy material such as steel, although molded
plastic and fiberglass have been used. Prior pans of this type
generally have a rectangular shape, with a flat bottom and
sidewalls about one and a half inches (1.5 in.) tall.
[0006] FIG. 1 shows a typical pan of this type. Pan 10 includes
bottom 12 and sidewalls 14, which extend substantially
perpendicular from the perimeter of bottom 12 and include drainage
portals 16. Condensate passes out of the pan through the portals,
normally into drainage hoses which direct it away from the pan. In
prior pans of this type, bottom 12 is flat. Since nautical vessels
generally do not remain level during operation, condensate often
pools and collects in the corners of the pan, e.g., condensate 18,
and is unable to pass out of the pan through the drainage portals.
Further, drainage portals 16 are usually located a small distance
above the juncture of the bottom and the sidewalls, in order to
allow room and proper support for drainage hose fittings 20.
Consequently, a problem occurs as the condensate collected in the
pan cannot drain out of the pan until it reaches a level high
enough to pass into openings 22 of drainage hose fittings 20. As
shown in FIG. 2, condensate 18 is below the height opening 22 of
hose fitting 20 and therefore is unable to drain out of pan 10,
leaving a pool of condensate 18 to stagnate. Over time, the
stagnant water, i.e., condensate 18, may become fetid and an
environmental hazard as bacteria and other species begin to grow in
it.
[0007] Another problem with marine air conditioners is the
vibration produced by the compressors. Compressors are available in
many configurations and types, for example, rotary and reciprocal,
horizontal or vertical. Regardless of the type, compressors tend to
produce an undesirable vibration and noise when they are operating.
This problem is exacerbated aboard a nautical vessel where the AC
unit is mounted in close proximity to passengers. Since the AC unit
must be securely mounted to a substructure, such as, the floor of
the vessel, the vibrations of the compressor are transmitted
through the substructure, which is then felt and/or heard by the
passengers. As boats are typically made of materials that are flat
and not very stiff, e.g., fiberglass, plywood, or sheet aluminum,
the substructure readily transmits and may even amplify the
vibration.
[0008] Commonly, a layer of foam about one-eighth of an inch (1/8
in.) thick is included underneath the bottom of a pan, to support
the pan uniformly, dampen some of the vibration, and provide a
thermal barrier to prevent the sweating of the pan onto the
surrounding areas. As shown in FIG. 3, pan 10 rests on layer of
foam 24 and is held in place with metal clips 26 that mechanically
and directly attach to the sides of the pan. Bolts 28 secure clips
26 to substructure 30. Because pan 10 is completely supported by
foam 24, foam 24 only partially absorbs vibration before
substructure 30 of the vessel (not shown) begins to vibrate.
Additionally, bolts 28 and clips 26 readily transmit vibration down
to substructure 30 due to contact between the same at interface
32.
[0009] FIG. 4 shows an alternative to the arrangement shown in FIG.
3, wherein pan 10 is secured to platform 34 with clips 26. Platform
34 is separated from substructure 30 and secured to elastic mounts
36 with bolts 38a. Elastic mounts 36 are secured to substructure 30
with bolts 38b. Typically, four elastic mounts 36 are employed
under the four corners of platform 34. While this alternative
arrangement performs better than the arrangement shown in FIG. 3
with respect to dampening the vibration of the compressor, a
significant amount of vibration is still transmitted into
substructure 30 as mounts 36 have the effect of focusing the force
of the vibration at each point of attachment to substructure 30.
Additionally, this type of platform assembly may cost as much as
fifteen percent (15%) or more of the cost of the complete AC unit,
making it quite expensive.
[0010] It is important to note, that the vertical height of the
unit is critical. There is very little vertical space under a bunk
or seating area, typically about thirteen inches (13 in.), and
placing a self-contained AC unit on the platform elevates the
assembly's position by approximately one and a half inches (1.5
in.), or about ten percent (10%) of the original height. This is
usually not possible as the overall height of an AC unit is
determined by the commercially available compressors used. This
forces the structural pans to be flat in nature in order to keep
the top of the compressor as low as possible.
[0011] As can be derived from the variety of devices and methods
directed at effectively collecting and draining condensate from a
marine AC unit, and damping the vibration produced thereby, many
means have been contemplated to accomplish the desired end, i.e.,
flat pans and flat pans elevated on a platform. Heretofore,
tradeoffs between space, effective draining and vibration damping
were required. Thus, there is a long-felt need for a condensation
collection pan for a marine AC unit that can effectively support
the AC unit, drain collected condensate, dampen the vibration, and
fit within the requisite space.
BRIEF SUMMARY OF THE INVENTION
[0012] The present invention broadly includes a pan for supporting
an AC unit and for collecting condensate produced by the AC unit.
The pan includes a bottom having surfaces at various elevations and
angles, which serve to secure an AC unit to the pan and/or direct
condensate out of the pan. The particular configuration of the
surfaces, in conjunction with mounting rails that separate the pan
from the underlying substructure, serve to dampen the vibrations
produced by the AC unit and retard their transmission to the
underlying substructure.
[0013] In one embodiment, the present invention broadly comprises a
mounting and collection pan for an air conditioning unit including
a bottom portion having a perimeter, a first flow surface and a
first substantially horizontal mounting surface, a sidewall
extending upwardly from the perimeter and a first portal arranged
in the sidewall. The first substantially horizontal mounting
surface includes a first means for securing the air conditioning
unit thereto and is elevationally higher than the first flow
surface. The first flow surface is angled to direct a liquid
condensate collected from the air conditioning unit to the first
portal via gravity. In some embodiments, the sidewall extends
substantially perpendicular from the bottom portion, while in other
embodiments, the sidewall includes a second portal and the first
flow surface is angled to direct the liquid condensate to the first
and second portals.
[0014] In still yet other embodiments, the mounting and collection
pan further includes a trough integral to the bottom portion having
first and second ends proximate the sidewall, wherein the trough is
elevationally lower than the first flow surface, the first flow
surface is angled to direct the liquid condensate to the trough,
and the trough directs the liquid condensate to the first portal.
In some of these embodiments, the bottom portion further includes a
second flow surface angled to direct the liquid condensate to the
trough, while in others of these embodiments, the trough extends
substantially along a centerline of the pan. In still yet others of
these embodiments, the first and second ends are elevationally
lower than the trough and one of the first and second ends is
proximate the first portal. In yet others of these embodiments, the
mounting and collection pan includes a second portal arranged in
the sidewall, wherein the trough directs the liquid condensate to
the first and second portals, and in some of these embodiments, the
first and second ends are elevationally lower than the trough and
proximate the first and second portals, respectively.
[0015] In some embodiments, the first means for securing the air
conditioning unit includes at least one opening for receiving
bolts. In other embodiments, the bottom portion further includes a
second mounting surface substantially coplanar with the first
mounting surface, the second mounting surface comprising a second
means for securing the air conditioning unit thereto, and in some
of these embodiments, the second means for securing the air
conditioning unit includes at least one opening for receiving
bolts. In yet other embodiments, the mounting and collection pan
further includes a flange having means for securing the pan to a
substructure, wherein the flange extends substantially
perpendicular from the sidewall on an edge of the sidewall distal
from the perimeter, and in some of these embodiments, the means for
securing the pan to the substructure includes a plurality of
openings through the flange, each of the plurality of openings
arranged for receiving a bolt therethrough, the bolt extending into
the substructure. In still further embodiments, the mounting and
collection pan includes a plurality of bushings, wherein each of
the plurality of bushings is positioned in one of the plurality of
openings and arranged for receiving the bolt therethrough, and in
some of these embodiments, each of the plurality of bushings
includes a vertical surface and a horizontal surface, the vertical
surface arranged to dampen a horizontal vibration of the pan and
the horizontal surface arranged to dampen a vertical vibration of
the pan.
[0016] In yet other embodiments, the mounting and collection pan
includes a first rail and a second rail fixedly secured to a lower
surface of the bottom portion and arranged to separate the pan from
a substructure. In some of these embodiments, the first and second
rails are constructed from an elastomer, while in others of these
embodiments, the first and second rails each include a linear
member.
[0017] In still another embodiment, the present invention broadly
comprises a mounting and collection pan for an air conditioning
unit including a bottom portion having a perimeter and a first flow
surface, a sidewall extending upwardly from the perimeter and a
first portal arranged in the sidewall. The air conditioning unit is
secured to the bottom portion and the first flow surface is angled
to direct a liquid condensate collected from the air conditioning
unit to the first portal via gravity. In some embodiments, the
bottom portion further includes a first substantially horizontal
mounting surface having a first means for securing the air
conditioner unit thereto and is elevationally higher than the first
flow surface.
[0018] In still yet another embodiment, the present invention
broadly comprises a mounting and collection pan for an air
conditioning unit including a bottom portion having a perimeter, a
first flow surface and a first substantially horizontal mounting
surface, a sidewall extending upwardly from the perimeter and a
first portal arranged in the sidewall and elevationally lower than
the first flow surface. The first substantially horizontal mounting
surface includes a first means for securing the air conditioning
unit thereto and is elevationally higher than the first flow
surface. The first flow surface is angled to direct a liquid
condensate collected from the air conditioning unit to the first
portal via gravity.
[0019] In yet another embodiment, the present invention broadly
comprises an air conditioning unit including a blower, an
evaporator, a condenser and a compressor. The compressor is
arranged in fluid communication the evaporator and condenser, the
evaporator is arranged in fluid communication with the condenser
and the blower is arranged to exchange a volume of air over the
evaporator. The air conditioning unit further includes a mounting
and collection pan having a bottom portion which includes a
perimeter, a first flow surface and a first substantially
horizontal mounting surface, a sidewall extending upwardly from the
perimeter and a first portal arranged in the sidewall. The first
substantially horizontal mounting surface includes a first means
for securing at least one of the blower, the evaporator, the
condenser and the compressor thereto and is elevationally higher
than the first flow surface. The first flow surface is angled to
direct a liquid condensate collected from the blower, the
evaporator, the condenser or the compressor to the first portal via
gravity.
[0020] In still yet another embodiment, the present invention
broadly comprises an air conditioning unit including a blower, an
evaporator, a condenser and a compressor. The compressor is
arranged in fluid communication the evaporator and condenser, the
evaporator is arranged in fluid communication with the condenser
and the blower is arranged to exchange a volume of air over the
evaporator. The air conditioning unit further includes a mounting
and collection pan having a bottom portion which includes a
perimeter, a first flow surface and a first substantially
horizontal mounting surface, a sidewall extending upwardly from the
perimeter and a first rail and a second rail fixedly secured to a
lower surface of said bottom portion and arranged to separate said
pan from a substructure. The air conditioning unit still further
includes a first portal arranged in the sidewall and elevationally
lower than said first flow surface. The first substantially
horizontal mounting surface includes a first means for securing at
least one of the blower, the evaporator, the condenser and the
compressor thereto and is elevationally higher than the first flow
surface. The first flow surface is angled to direct a liquid
condensate collected from the blower, the evaporator, the condenser
or the compressor to the first portal via gravity.
[0021] It is a general object of the present invention to provide a
condensate collection pan that can support the weight of an air
conditioner unit.
[0022] It is another general object of the present invention to
provide a condensate collection pan that can effectively absorb and
disperse vibrations produced by an air conditioner unit.
[0023] It is yet another object of the present invention to provide
a condensate collection pan of this type that can effectively drain
condensate and/or other liquid accumulated in the pan.
[0024] It is still yet another object of the present invention to
provide a condensate collection pan having the previously described
benefits which does not substantially increase the overall height
of an AC unit relative to its mounting location.
[0025] These and other objects and advantages of the present
invention will be readily appreciable from the following
description of preferred embodiments of the invention and from the
accompanying drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The nature and mode of operation of the present invention
will now be more fully described in the following detailed
description of the invention taken with the accompanying drawing
figures, in which:
[0027] FIG. 1 is a perspective view of a prior art condensate
collection pan;
[0028] FIG. 2 is a cross sectional view of the prior art condensate
collection pan having a hose fitting installed therein;
[0029] FIG. 3 is a cross sectional view of the prior art condensate
collection pan fixedly secured to a substructure;
[0030] FIG. 4 is a cross-sectional view of the prior art condensate
collection pan fixedly secured to a platform above the
substructure;
[0031] FIG. 5a is a top plan view of a present invention condensate
collection pan having a compressor installed thereon;
[0032] FIG. 5b is a side elevational view of the condensate
collection pan and compressor shown in FIG. 5a;
[0033] FIG. 5c is a front elevational view of the condensate
collection pan and compressor shown in FIG. 5a;
[0034] FIG. 5d is a perspective view of the condensate collection
pan and compressor shown in FIG. 5a;
[0035] FIG. 5e is a cross-sectional view of the condensate
collection pan and compressor shown in FIG. 5a taken generally
along line 5e-5e of FIG. 5a;
[0036] FIG. 6a is a top plan view of an embodiment of the present
invention condensate collection pan with a hose fitting installed
therein;
[0037] FIG. 6b is a cross-sectional view of the condensate
collection pan and hose fittings taken generally along line 6b-6b
of FIG. 6a;
[0038] FIG. 6c is an enlarged cross-sectional view of the
condensate collection pan and hose fittings shown in encircled
region 6c of FIG. 6b;
[0039] FIG. 7a is a partial top plan view of an embodiment of the
present invention condensate collection pan;
[0040] FIG. 7b is a cross-sectional view of an embodiment of the
present invention condensate collection pan fixedly secured to a
substructure taken generally along line 7b-7b of FIG. 7a;
[0041] FIG. 7c is an enlarged cross-sectional view of the portion
of the condensate collection pan and bushing shown in encircled
region 7c of FIG. 7b; and,
[0042] FIG. 8 is a perspective view of the condensate collection
pan having an air conditioning unit installed therein.
DETAILED DESCRIPTION OF THE INVENTION
[0043] At the outset, it should be appreciated that like drawing
numbers on different drawing views identify identical, or
functionally similar, structural elements of the invention. While
the present invention is described with respect to what is
presently considered to be the preferred embodiments, it is to be
understood that the invention as claimed is not limited to the
disclosed embodiments.
[0044] Furthermore, it is understood that this invention is not
limited to the particular methodology, materials and modifications
described and as such may, of course, vary. It is also understood
that the terminology used herein is for the purpose of describing
particular aspects and embodiments only, and is not intended to
limit the scope of the present invention, which is limited only by
the appended claims.
[0045] Unless defined otherwise, all technical and scientific terms
used herein have the same meaning as commonly understood to one of
ordinary skill in the art to which this invention belongs. Although
any methods, devices or materials similar or equivalent to those
described herein can be used in the practice or testing of the
invention, the preferred methods, devices, and materials are now
described.
[0046] Adverting now to the figures, FIGS. 5a through 5e show an
embodiment of pan 50 of the instant invention. Pan 50 may be used
under any marine AC unit or sub-assembly that collects liquid
condensate and is intended to be self-draining at all moderate
angles of heal and running conditions of a nautical vessel. Pan 50
has a generally rectangular shape, however other shapes are also
possible and within the spirit and scope of the invention as
claimed, e.g., square, circular, etc. Additionally, pan 50 includes
bottom 52 and sidewall 54, which extends approximately
perpendicular from perimeter 56 of bottom 52. Drainage portals 58a
and 58b are arranged in sidewall 54. In the embodiment of the
present invention pan shown in the figures, sidewall 54 is a single
continuous wall enclosing bottom 52 which has a substantially
rectangular shape but with rounded corners. However, sidewall 54
may also exist as discrete sections when bottom 52 has a polygonal
shape, i.e., a rectangle.
[0047] Bottom 52 includes mounting surfaces 60a, 60b, and 60c and
flow surfaces 62, 64a, 64b, and 64c. Mounting surfaces 60a-c are
substantially horizontal and coplanar, are elevationally higher
with respect to flow surfaces 62, 64a, 64b, and 64c, and
operatively arranged to direct liquid to flow surfaces 62, 64a,
64b, and 64c. Collectively, mounting surfaces 60a and 60b form one
surface for mounting a compressor of an AC unit, while
alternatively, mounting surfaces 60a and 60c form another surface
for mounting a compressor of an AC unit. As one of ordinary skill
in the art appreciates, various arrangements of an AC unit are
possible, e.g., a left or right handed unit, and pan 50 is arranged
to accommodate a plurality of such configurations. Mounting
surfaces 60a-c may include means for securing an AC unit, or a
component thereof, to the pan. It should be appreciated that in the
embodiment shown in FIGS. 5a-5e, only compressor 66 of an AC unit
is shown, as showing the entire AC unit would obstruct the view of
pan 50. In these figures, mounting plate 68 of compressor 66 is
secured to mounting surfaces 60a and 60c by means of bolts 70,
which extend through the plate and are secured in openings 72 (see
FIGS. 6a and 7a) which are arranged through mounting surfaces
60a-c. As can be ascertained from the drawings and described supra,
mounting surfaces 60a-c are arranged such that components of an AC
unit, e.g., compressor 66, may be secured to pan 50 at various
positions, as long as the appropriate means for securing the
components are provided. For example, compressor 66 could readily
be secured on the reverse side of pan 50 were openings 72 provided
on the opposite end of mounting surface 60a as well as 60b. As one
of ordinary skill in the art appreciates, mounting plate 68 may
include standoffs 74, which serve to mitigate vibrations produced
by compressor 66. It should further be appreciated that although in
these embodiments mounting surfaces 60a-c are shown integral to pan
50, other embodiments are also possible, e.g., pads mounted to the
underside of an AC unit components thereby providing means to
matingly engage the AC unit with pan 50, and such embodiments are
within the spirit and scope of the claimed invention.
[0048] It has been contemplated that the present invention pan 50
may include only one flow surface, e.g., flow surfaces 62 or
collectively flow surfaces 64a, 64b, and 64c, operatively angled to
direct liquid condensate from the AC unit to at least a first
drainage portal, e.g., portal 58a or portal 58b. However, in a
preferred embodiment, at least two flow surfaces are included,
e.g., flow surfaces 62 and collectively flow surfaces 64a, 64b, and
64c, operatively angled downward toward centerline 76 and terminate
at trough 78, which directs liquid condensate to at least one
drainage portal, e.g., portal 58a or portal 58b, and in a further
preferred embodiment, directs liquid condensate to both portal 58a
and portal 58b. In the embodiment shown in FIGS. 5a through 7b,
flow surface 62 operates as a first flow surface, while
collectively flow surfaces 64a, 64b, and 64c operate as a second
flow surface. It should be appreciated that in some embodiments,
drainage portals 58a and/or 58b are elevationally lower than flow
surfaces 62, 64a, 64b and 64c, and in this instance, "elevationally
lower than" is intended to mean that drainage portals 58a and/or
58b are below the lowest points or areas of flow surfaces 62, 64a,
64b and 64c. Therefore, liquid condensate flows along flow surfaces
62, 64a, 64b and 64c to their lowest points or areas and
subsequently into drainage portals 58a and/or 58b. Both flow
surfaces are operatively angled toward centerline 76 and direct
liquid condensate to trough 78, i.e., a surface elevationally lower
than both flow surfaces. Trough 78 extends along centerline 76 and
terminates at opposing sections of sidewall 54, i.e., first and
second end regions 80a and 80b, respectively. Thus, trough 78
includes first end region 80a and second end region 80b, and is
operatively configured to direct liquid to first end region 80a
and/or second end region 80b. It should be appreciated that first
and second end regions 80a and 80b, respectively, are located
elevationally lower than trough 78 and therefore liquid condensate
flows from trough 78 into first and second end regions 80a and 80b,
respectively. In this instance, "elevationally lower than" is
intended to mean that first and second end regions 80a and 80b,
respectively, are below the lowest point or area of trough 78.
Drainage portals 58a and 58b are in fluid communication with end
regions 80a and 80b, and may include means for securing a hose to
the drainage portals, such as, attachment 82, shown in FIGS. 6b and
6c.
[0049] In view of the foregoing arrangement, effective drainage is
provided by the present invention pan 50. As a liquid, such as,
condensate, is produced by an AC unit, the liquid flows downward
via gravity from the AC unit to one or more mounting surfaces, then
to one or more flow surfaces, which direct it to a trough, which in
turn directs it to the end regions of the trough, and finally out
of the pan through one or more drainage portals. Because of the
aforementioned configuration of surfaces, liquid condensate is
continuously directed toward one or more drainage portals, which
causes a continuous flushing of the trough and end regions, and,
hence, does not allow liquid to stagnate. Additionally, due to the
above described configuration, only a small amount of water may
pool in end regions 80a and 80b, and therefore a minimum amount of
stagnation can occur.
[0050] In a preferred embodiment, as shown in the figures, flow
surfaces 62, 64a, 64b, and 64c are angled downward toward
centerline 76, which gives pan 50 a V-shape. The present invention
further includes a pair of rails 84a and 84b that separate pan 50
from underlying substructure 86. Rails 84a and 84b extend parallel
to centerline 76, preferably near the underside of sidewall 54.
Rails 84a and 84b, in conjunction with V-shaped pan 50, provide a
second order of vibration damping, as the static weight of the AC
unit rests primarily on the "V" portion of pan 50, which is
suspended above substructure 86. As compressor 66 vibrates,
standoffs 74 initially absorb some of the vibration, followed by
V-shaped pan 50, which can freely oscillate in the vertical
direction without affecting substructure 86. Rails 84a and 84b, in
turn, dissipate any residual vibration along the line of contact
with substructure 86 beneath them. As shown in FIG. 7b, first rail
84a and second rail 84b separate pan 50 from substructure 86. Rails
84a and 84b may be made from any material. However, in a preferred
embodiment, the material is an elastomer. For example, rails 84a
and 84b shown in FIGS. 5b through 5e and 7b may be linear extruded
EPDM rubber gaskets and are attached to pan 50 using a strong
pressure sensitive adhesive. By using rails 84a and 84b to separate
pan 50 from substructure 86, any vibration from compressor 66 which
is not absorbed by either standoffs 74 or pan 50 itself, is
dissipated along the length of rails 84a and 84b. It should be
appreciated that the present invention as claimed may include more
than the two rails shown in the figures and that the rails may only
extend along a portion of the length of pan 50. For example, the
present invention may comprise four rails each disposed proximate
one of the four corner regions of the lower surface of bottom
portion 52, and each of these rails may only extend a quarter of
the length of bottom portion 52. Additionally, it should be
appreciated that although rails 84a and 84b are shown arranged
parallel to centerline 76, it is also within the spirit and scope
of the claimed invention to arrange rails perpendicular to
centerline 76. Furthermore, each rail may be constructed from a
different material to accommodate variable localized masses, e.g.,
a condenser which weighs more than a blower, and such variations
are within the spirit and scope of the claimed invention.
[0051] The above described rail design also resists lateral
movement while allowing for vertical movement. Pan 50 may be
secured to substructure 86 by any means known in the art, but
preferably by bolts 88 which extend through openings 90 defined by
flange 92. Flange 92 extends substantially perpendicular from
sidewall 54 at edge 94, i.e., the edge of sidewall 54 distal from
perimeter 56. Flange 92 includes a plurality of bushings 96, each
inserted within an opening 90 which isolate pan 50 from attachment
bolts 88. Bushings 96 each include horizontal surface 98 and
vertical surface 100. It should be appreciated that horizontal
surface 98 dampens vibration in the vertical direction, while
vertical surface 100 dampens vibration in the horizontal direction.
Thus, bolts 88 may be completely isolated from pan 50 both
vertically and horizontally. Bushing 96, arranged around the head
of bolt 88, will only be compressed if the entire AC unit tries to
move due to violent motion of the vessel, and not because of any
vibration or vertical oscillation created by the normal operation
of compressor 66. It should be appreciated that in a preferred
embodiment, bolts 88 are preloaded so that some pressure is applied
to rails 84a and 84b, however, rails 84a and 84b are not fully
compressed.
[0052] Another advantage of the present invention is that pan 50
may be formed using a low modulus material, for example,
fiberglass. Pan 50 may also be made of a vacuum-formed material, or
an injection molded material. By using a low modulus material, pan
50 is allowed to vibrate and dissipate some energy before the outer
edge of pan 50 moves and transmits the vibration down into rails
84a and 84b.
[0053] As described supra, a further embodiment of the present
invention includes the mounting and collection pan in combination
with an AC unit. FIG. 8 shows a perspective view of condensate
collection pan 50 having air conditioning unit 102 installed
therein. As also described supra, the basic components of air
conditioning unit 102 include blower 104, evaporator 106, condenser
108 and compressor 66. Compressor 66 is arranged in fluid
communication with evaporator 106 and condenser 108, while
evaporator 106 is arranged in fluid communication with condenser
108. Blower 104 is arranged to exchange a volume of air over
evaporator 106 thereby cooling the volume of air. Thus, it should
be appreciated that the arrangement of pan 50 allows AC unit 102 to
be positioned for right or left handed use, i.e., positioned on the
right or left side of a marine vessel thereby providing cooled air
in the desired area of the vessel. Additionally, any liquid
condensate forming on AC unit 102 is captured by pan 50 and
disposed of according to the above described conditions. Similarly,
as described above, pan 50 may include rails 84a and 84b fixedly
secured to a lower surface of bottom portion 52 and are arranged to
separate pan 50 from substructure 86, while portals 58a and/or 58b
are arranged in sidewall 54 and are elevationally lower than flow
surfaces 62, 64a, 64b and 64c. In this instance, as described
above, "elevationally lower than" is intended to mean that drainage
portals 58a and/or 58b are below the lowest points or areas of flow
surfaces 62, 64a, 64b and 64c.
[0054] Accordingly, the drain feature, rails and structural pan
arrangement enable the separation of pan 50 from substructure 86
without increasing the overall height of the assembly. Contrarily,
as described in the BACKGROUND OF THE INVENTION, placing a standard
pan on a thick foam strip or mounting it on rubber shocks would
increase the overall height of the assembly. Thus, the present
invention arrangement provides superior vibration isolation for the
AC unit, while providing a convenient and efficient means of
exhausting liquid condensate from the assembly, thereby minimizing
the possibility of stagnate water, i.e., unpleasant odor and/or
biological contaminants.
[0055] Thus, it is seen that the objects of the present invention
are efficiently obtained, although modifications and changes to the
invention should be readily apparent to those having ordinary skill
in the art, which modifications are intended to be within the
spirit and scope of the invention as claimed. It also is understood
that the foregoing description is illustrative of the present
invention and should not be considered as limiting. Therefore,
other embodiments of the present invention are possible without
departing from the spirit and scope of the present invention.
* * * * *