U.S. patent application number 11/527217 was filed with the patent office on 2008-04-24 for support bracket for casing of a condensing unit.
This patent application is currently assigned to Carrier Corporation. Invention is credited to Larry D. Burns, Loren D. Hoffman, Derek Leman, Louis J. Sullivan.
Application Number | 20080092576 11/527217 |
Document ID | / |
Family ID | 39316606 |
Filed Date | 2008-04-24 |
United States Patent
Application |
20080092576 |
Kind Code |
A1 |
Hoffman; Loren D. ; et
al. |
April 24, 2008 |
Support bracket for casing of a condensing unit
Abstract
A support bracket suitable for use in a casing of an outdoor
condensing unit includes a main body configured to reside between a
corner post and a coil of the condensing unit, a first extension
member extending from a first end of the main body, and a second
extension member extending from a second end of the main body. The
first extension member is configured to attach to a first inlet
grille of the condensing unit. The second extension member is
configured to attach to a second inlet grille of the condensing
unit.
Inventors: |
Hoffman; Loren D.;
(Indianapolis, IN) ; Burns; Larry D.; (Avon,
IN) ; Sullivan; Louis J.; (Indianapolis, IN) ;
Leman; Derek; (Brownsburg, IN) |
Correspondence
Address: |
KINNEY & LANGE, P.A.
THE KINNEY & LANGE BUILDING, 312 SOUTH THIRD STREET
MINNEAPOLIS
MN
55415-1002
US
|
Assignee: |
Carrier Corporation
Farmington
CT
|
Family ID: |
39316606 |
Appl. No.: |
11/527217 |
Filed: |
September 26, 2006 |
Current U.S.
Class: |
62/259.1 |
Current CPC
Class: |
F24F 1/50 20130101; F24F
1/60 20130101; F25D 23/00 20130101; F24F 1/56 20130101 |
Class at
Publication: |
62/259.1 |
International
Class: |
F25D 23/12 20060101
F25D023/12 |
Claims
1. A support bracket suitable for use in a casing of an outdoor
condensing unit, the support bracket comprising: a main body
configured to reside between a corner post and a coil of the
condensing unit; a first extension member extending from a first
end of the main body; and a second extension member extending from
a second end of the main body, wherein the first extension member
is configured to engage with a first inlet grille of the condensing
unit and the second extension member is configured to engage with a
second inlet grille of the condensing unit.
2. The support bracket of claim 1, wherein the main body comprises
a first tab member and a second tab member that are each configured
to engage with the corner post.
3. The support bracket of claim 2, wherein the first and the second
tab members each include a dimple configured to align with a first
hole and a second hole of the corner post.
4. The support bracket of claim 1, wherein the first extension
member includes an aperture for receiving a fastener through the
first extension member to attach the first extension member to a
post of the first inlet grille.
5. The support bracket of claim 1, wherein the main body comprises
a rib member configured to provide rigidity to the main body.
6. The support bracket of claim 1, wherein the first extension
member further comprises a first end portion extending from an end
of the first extension member opposite to the main body and
configured to contact the coil of the condensing unit.
7. The support bracket of claim 1, wherein the support bracket is
formed from sheet metal.
8. A protective casing for a condenser coil, the protective casing
comprising: a first inlet grille; a second inlet grille; a corner
post positioned between the first and second inlet grilles; and a
support bracket comprising: a main body positioned between the
corner post and the condenser coil; and a first extension member
and a second extension member extending from opposite ends of the
main body and configured such that the first extension member is
attachable to the first inlet grille and the second extension
member is attachable to the second inlet grille.
9. The protective casing of claim 8, wherein the first extension
member includes an aperture and the first inlet grille includes a
top post, and a fastener is received through the aperture of the
first extension member and engaged with the top post to attach the
support bracket to the first inlet grille.
10. The protective casing of claim 8, wherein the main body of the
support bracket includes a pair of tab members configured to engage
with the corner post.
11. The protective casing of claim 10, wherein the tab members hook
onto the corner post to secure the support bracket to the corner
post.
12. The protective casing of claim 8 further comprising a top cover
configured to attach to the corner post and to the support
bracket.
13. The protective casing of claim 12, wherein the top cover is
configured to attach to the corner post at a first attachment
point, to the first inlet grille and the first extension member at
a second attachment point, and to the second inlet grille and the
second extension member at a third attachment point.
14. The protective casing of claim 8, wherein the first extension
member includes a corner portion configured to engage with a first
flange on the corner post, and the second extension member includes
a corner portion configured to engage with a second flange on the
corner post.
15. A method of protecting a coil assembly for a condensing unit,
the method comprising: securing an inlet grille around an outside
of the coil assembly; securing a corner post around an outside
corner portion of the coil assembly; and supporting the inlet
grille at a top portion of the inlet grille such that the inlet
grille is essentially immobile; and supporting the corner post such
that the corner post is essentially immobile.
16. The method of claim 15, wherein a support bracket is used to
support the inlet grille at the top portion of the inlet
grille.
17. The method of claim 16, wherein a fastener is received through
an aperture in the support bracket and engaged with a hole in the
inlet grille.
18. The method of claim 15, wherein a support bracket is used to
support the corner post and a portion of the support bracket
attaches to the corner post.
19. The method of claim 15 further comprising: positioning a top
cover over the coil assembly; securing the top cover to the inlet
grille; and securing the top cover to the corner post.
20. The method of claim 19, wherein securing the top cover to the
inlet grille includes positioning a support bracket between the top
cover and the inlet grille.
21. The method of claim 19 further comprising: shielding the coil
assembly from being punctured by a fastener used to secure the top
cover to the corner post.
22. The method of claim 21, wherein a support bracket positioned
between the corner post and the coil assembly is used to shield the
coil assembly.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to a support. More
particularly, the present invention relates to a support bracket
configured to support a protective casing for a condenser coil.
[0002] A split system heating and/or cooling system includes an
outdoor unit, such as a condensing unit, and an indoor unit, such
as an evaporator unit. The condensing unit typically includes a
condenser coil, inlet grilles for protecting the coil, a top cover,
and a base pan for containing the condensing unit and receiving
condensation that drips from the coil.
[0003] Commonly, the condensing unit includes an inlet grille on
each of the four sides of the condensing unit. A corner post may be
used at the corners of the condensing unit to secure each end of
the inlet grilles.
BRIEF SUMMARY OF THE INVENTION
[0004] The present invention relates to a support bracket suitable
for use in a casing of an outdoor condensing unit. The support
bracket includes a main body configured to reside between a corner
post and a coil of the condensing unit, a first extension member
extending from a first end of the main body, and a second extension
member extending from a second end of the main body. The first
extension member is configured to attach to a first inlet grille of
the condensing unit. The second extension member is configured to
attach to a second inlet grille of the condensing unit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a perspective view of an outdoor condensing
unit.
[0006] FIG. 2A is a perspective view of an embodiment of a support
bracket.
[0007] FIG. 2B is a top view of the support bracket of FIG. 2A.
[0008] FIG. 2C is a cross-sectional view of a portion of the
support bracket of FIG. 2B.
[0009] FIG. 2D is a cross-sectional view of another portion of the
support bracket of FIG. 2B.
[0010] FIG. 3 is a perspective view of a portion of the outdoor
condensing unit of FIG. 1 with a top cover of the unit removed.
DETAILED DESCRIPTION
[0011] FIG. 1 is a perspective view of outdoor condensing unit 10
of an air conditioning or heat pump system. Condensing unit 10
includes fan 12, coil assembly 14 (not shown in FIG. 1; see FIG.
3), top cover 16, first inlet grille 18, second inlet grille 20,
base pan 22, first corner post 24, control box 26, and second
corner post 28.
[0012] First inlet grille 18 and second inlet grille 20 are
configured for protecting coil assembly 14, which includes copper
tubing and thin aluminum fins that are used to form a coil.
Condensing unit 10 includes two additional inlet grilles, which are
not visible in FIG. 1. A third inlet grille is located on an
opposing side of first inlet grille 18, and a fourth inlet grille
is located on an opposing side of second inlet grille 20.
[0013] First corner post 24 resides between first and second inlet
grilles 18 and 20, and also protects coil assembly 14. Corner post
24 may be attached to top cover 16 and to base pan 14. First and
second inlet grilles 18 and 20 may also be attached to top cover 16
and to base pan 14. A portion of second corner post 28 is also
visible in FIG. 1 and resides between first inlet grille 18 and the
fourth inlet grille. A third corner post (not visible in FIG. 1) is
located opposite to first corner post 24 and resides between the
third and fourth inlet grilles. The corner posts and inlet grilles
of unit 10 form a protective casing around coil assembly 14. Top
cover 16 also may be part of the protective casing of condensing
unit 10.
[0014] Although the discussion below is in reference to first inlet
grille 18, second inlet grille 20, and first corner post 24, this
discussion also applies to the other inlet grilles and corner posts
of condensing unit 10.
[0015] During manufacturing and assembly of condensing unit 10, top
cover 16 may be attached to unit 10. Top cover 16 may be assembled
onto unit 10 during the final or near final steps of the
manufacturing and assembly process. Top cover 16 may serve as a
support for inlet grilles 18 and 20 near a top portion of coil
assembly 14. Thus, inlet grilles 18 and 20 may not be supported
near a top portion of coil assembly 14 until top cover 16 is
attached to unit 10. As a result of this lack of support, inlet
grilles 18 and 20 may bow away from coil assembly 14 during
assembly of condensing unit 10. If inlet grilles 18 and 20 bend
beyond a certain point, the structural integrity of the grilles may
be comprised, which may lead to failure or breakage.
[0016] In order to attach top cover 16 to corner post 24, an
aperture in a center of a top portion of corner post 24 may be used
to receive a fastener that first passes through top cover 16. If
only one fastener is used to fix top cover 16 to corner post 24,
corner post 24 may not be adequately secured to top cover 16, in
terms of preventing movement of corner post 24. As such, the sides
of corner post 24 may be able to bend around a center of corner
post 24 and rattle against top cover 16.
[0017] Inlet grilles 18 and 20 and corner post 24 are configured as
a cage or casing around coil assembly 14 to protect the coil.
However, in designs as described above, in which a fastener is used
to fix top cover 16 to corner post 24, an end of the fastener may
likely puncture the coil during shipping or assembly.
[0018] The present invention relates to a support bracket suitable
for use in outdoor condensing unit 10 in order to provide support
to inlet grilles 18 and 20 and corner post 24, as well as protect
coil assembly 14. The support bracket is configured to eliminate
the potential for the problems mentioned above.
[0019] FIG. 2A is a perspective view of a preferred embodiment of a
support bracket in accordance with the present invention. As shown
in FIG. 2A, support bracket 30 includes main body portion 32, first
tab member 34a, second tab member 34b, first extension member 36a,
and second extension member 36b. First extension member 36a
includes first corner portion 38a, first fastener portion 40a, and
first end portion 42a. Similarly, second extension member 36b
includes second corner portion 38b, second fastener portion 40b,
and second end portion 42b.
[0020] As described in more detail below, support bracket 30 is
configured to be located between corner post 24 and coil assembly
14 of FIG. 1 to support corner post 24 and protect the coil. In
addition, first extension member 36a and second extension member
36b are configured to support inlet grilles 18 and 20 of FIG.
1.
[0021] Main body portion 32 of support bracket 30 is configured to
be located behind corner post 24. Main body portion 32 includes rib
44, which provides rigidity to main body portion 32.
[0022] First tab member 34a and second tab member 34b are each
configured to engage with corner post 24, as described in further
detail below with reference to FIGS. 2B and 2C. First corner
portion 38a and second corner portion 38b are each configured to
engage with a flange on corner post 24, as discussed below in
reference to FIG. 3. First fastener portion 40a, having aperture
46a, is configured to engage with first inlet grille 18 and top
cover 16; similarly, second fastener portion 40b, having aperture
46b, is configured to engage with second inlet grille 20 and top
cover 16. First and second end portions 42a and 42b are configured
to press against the coil of coil assembly 14.
[0023] FIG. 2B is a top view of support bracket 30 of FIG. 2A,
which includes main body portion 32 having rib 44, first tab member
34a, second tab member 34b, first extension member 36a, and second
extension member 36b.
[0024] As shown in FIG. 2B, main body portion 32 has a length L1
and rib 44 has a length L2. In the embodiment of bracket 30 in
FIGS. 2A-2D, length L2 of rib 44 is approximately 65 percent of
length L1 of main body portion 32. It is recognized that rib 44 may
be various lengths, and in other embodiments, length L1 may be
smaller or greater than as shown in FIG. 2A.
[0025] First extension member 36a includes first corner portion
38a, which has long portion 48a extending from an end of tab member
34a and short portion 50a that connects with fastener portion 40a.
Long portion 48a and short portion 50a are oriented approximately
90 degrees relative to one another such that a flange on corner
post 24 is configured to rest against short portion 50a. Similarly,
second extension member 36b includes second corner portion 38b
having long portion 48b extending from an end of second tab member
34b and short portion 50b connecting to second fastener portion
40b. A second flange located on an opposite side of corner post 24
is configured to rest against short portion 50b of second corner
portion 38b. As shown in FIG. 3 below, first and second corner
portions 38a and 38b are configured to facilitate an interference
fit between corner post 24 and support bracket 30.
[0026] FIG. 2C is a cross-sectional view of first tab member 34a of
FIG. 2B. Tab member 34a includes front portion 52a and back portion
54a having dimple 56a. Tab member 34a is configured to engage with
corner post 24 such that front portion 52a may be inserted over
corner post 24 to secure bracket 30 to corner post 24, and back
portion 54a resides behind corner post 24. Dimple 56a of tab member
34a is configured to align with a hole on corner post 24. Tab
member 34b similarly has a dimple configured to align with another
hole on corner post 24.
[0027] FIG. 2D is a cross-sectional view of main body portion 32
including rib 44. As described above, rib 44 is used to provide
rigidity and additional structural support to main body portion 32
such that main body portion 32 is not able to flex. Rib 44 is
configured to rest against a back side of corner post 24. As shown
in FIG. 2D, main body portion 32 has a width W1 and rib 44 has a
width W2. In the embodiment of bracket 30 shown in FIGS. 2A-2D,
width W2 is approximately a third of width W1; however, it is
recognized that width W2 may be smaller or larger in other
embodiments.
[0028] Support bracket 30 is configured such that main body portion
32 is rigid, while first and second extension members 36a and 36b
are flexible. Support bracket 30 may be formed from any metal or
any other suitable material. In a preferred embodiment, support
bracket 30 may formed from a sheet metal made of steel. Support
bracket 30 may be formed by various known stamping techniques,
including, but not limited to, using a progressive die.
[0029] FIG. 3 is a perspective view of a portion of condensing unit
10 of FIG. 1, with top cover 16 removed from condensing unit 10.
FIG. 3 shows coil assembly 14, first inlet grille 18, corner post
24, second inlet grille 20, and support bracket 30 of FIGS. 2A-2D.
Although support bracket 30 is shown in FIG. 3 between first and
second inlet grilles 18 and 20 and behind corner post 24, it is
recognized that support bracket 30 may also be used to support
second corner post 28 and the third corner post, and the
corresponding inlet grilles. As such, condensing unit 10 of FIG. 1
may include three support brackets.
[0030] Corner post 24 includes aperture 60, which is located in a
center of corner post 24 and is configured for receiving a fastener
that attaches top cover 16 (not shown) to corner post 24. Because
main body portion 32 of support bracket 30 is located behind corner
post 24, support bracket 30 protects coil assembly 14 from being
punctured by the fastener received through corner post 24.
[0031] As shown in FIG. 3, front portion 52a of first tab member
34a is hooked over corner post 24; similarly, front portion 52b of
second tab member 34b is hooked over corner post 24 at an opposite
end of corner post 24. Although not visible in FIG. 3, back portion
54a of first tab member 34a is located behind corner post 24, and
dimple 56a aligns with a hole in corner post 24; similarly, back
portion 54b of second tab member 34b is located behind corner post
24, and a dimple on second tab member 34b aligns with a hole on an
opposite end of corner post 24.
[0032] As shown in FIG. 3, first inlet grille 18 includes post 62
having aperture 64. Support bracket 30 is configured such that
aperture 46a of first fastener portion 40a is aligned with aperture
64 of post 62. In order to attach top cover 16 to inlet grille 18,
a fastener is inserted through top cover 16 and then through
aperture 46a and aperture 64. Similarly, second inlet grille 20
includes post 66 having aperture 68. Aperture 46b of second
fastener portion 40b is aligned with aperture 68 of post 68 to
attach top cover 16 to inlet grille 20.
[0033] Support bracket 30 provides further support to corner post
24 by way of first corner portion 38a and second corner portion
38b. As explained above in reference to FIG. 2B, first corner
portion 38a includes long portion 48a and short portion 50a, which
are configured such that there is an interference fit between first
flange 70 of corner post 24 and first corner portion 38a.
Similarly, an interference fit exists between second flange 72,
located on an opposite side of corner post 24, and second corner
portion 38b. Support bracket 30 is configured such that first end
portion 42a and second end portion 42b each press against coil
assembly 14, as shown in FIG. 3.
[0034] To assemble a condensing unit similar to condensing unit 10
of FIGS. 1 and 3, which includes support bracket 30, a first step
is to attach a compressor to base pan 22 and then set coil assembly
14 into base pan 22. Next, a bottom portion of first inlet grille
18 may be attached to base pan 22 with fasteners, such as screws.
Bracket 30 may then be attached to corner post 24 by hooking first
and second tab members 34a and 34b onto corner post 24. Next, a
bottom portion of corner post 24 may be attached to base pan 22,
and fastener portion 40a of bracket 30 is aligned with post 62 of
inlet grille 18 such that bracket 30 is resting over inlet grille
18. Second inlet grille 20 may then be attached by first fastening
a bottom portion of second inlet grille 20 to base pan 22. Post 66
of second inlet grille 20 may then be placed behind support bracket
30 such that aperture 46b of fastener portion 40b is aligned with
aperture 68 of post 66.
[0035] These steps, attaching a grill, then a corner post, then a
second grill, are repeated until condensing unit 10 includes four
inlet grilles, three corner posts, and a control box. In reality,
assembly of unit 10 may likely begin with one of the inlet grilles
that are not visible in FIG. 1. As such, first inlet grille 18 may
actually be the third inlet grille to be assembled onto unit 10.
Similarly, corner post 24 may be the third and final corner post
assembled onto unit 10.
[0036] Finally, top cover 16 is placed on unit 10 and fasteners are
used to secure top cover 16 at various positions around unit 10. As
explained above, a fastener is received through top cover 16 and
aperture 60 of corner post 24 to attach top cover 16 and corner
post 24. In addition, a second fastener is received through top
cover 16, aperture 46a of support bracket 30, and aperture 64 of
first inlet grille 18. A third fastener is received through top
cover 16, aperture 46b of support bracket 30, and aperture 68 of
second inlet grille 20.
[0037] It is recognized that various methods may be used to
assemble condensing unit 10, in addition to or as an alternative to
the steps outlined above.
[0038] The terminology used herein is for the purpose of
description, not limitation. Specific structural and functional
details disclosed herein are not to be interpreted as limiting, but
merely as bases for teaching one skilled in the art to variously
employ the present invention. Although the present invention has
been described with reference to preferred embodiments, workers
skilled in the art will recognize that changes may be made in form
and detail without departing from the spirit and scope of the
invention.
* * * * *