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.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

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:

FIG. 1 is a perspective view of a prior art condensate collection pan;

FIG. 2 is a cross sectional view of the prior art condensate collection pan having a hose fitting installed therein;

FIG. 3 is a cross sectional view of the prior art condensate collection pan fixedly secured to a substructure;

FIG. 4 is a cross-sectional view of the prior art condensate collection pan fixedly secured to a platform above the substructure;

FIG. 5 a is a top plan view of a present invention condensate collection pan having a compressor installed thereon;

FIG. 5 b is a side elevational view of the condensate collection pan and compressor shown in FIG. 5a;

FIG. 5 c is a front elevational view of the condensate collection pan and compressor shown in FIG. 5a;

FIG. 5 d is a perspective view of the condensate collection pan and compressor shown in FIG. 5a;

FIG. 5 e 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;

FIG. 6 a is a top plan view of an embodiment of the present invention condensate collection pan with a hose fitting installed therein;

FIG. 6 b is a cross-sectional view of the condensate collection pan and hose fittings taken generally along line 6b-6b of FIG. 6a;

FIG. 6 c is an enlarged cross-sectional view of the condensate collection pan and hose fittings shown in encircled region 6c of FIG. 6b;

FIG. 7 a is a partial top plan view of an embodiment of the present invention condensate collection pan;

FIG. 7 b 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;

FIG. 7 c 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,

FIG. 8 is a perspective view of the condensate collection pan having an air conditioning unit installed therein.

DETAILED DESCRIPTION OF THE INVENTION

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.