Patent Application
20240377077
The invention relates generally to heating, ventilation and air conditioning (HVAC) system, and more particularly to partially-assembled HVAC systems and methods associated therewith.
Before, the biggest friction for the layperson to properly install a mini split (or other heat pump or split heating/air conditioning system) was the requirement to properly install a refrigerant line set. The first need here was to connect the male and female flared fittings with the proper torque at the line set connection points, and thus required a torque wrench. Too tight would mean potentially stripping the nut/bolt system, and too loose would mean the pressurized refrigerant would likely leak when the system was running after installation. In an effort to avoid such leaks, the line set needed to be formally tested for refrigerant leaks by releasing pressurized nitrogen into the system (and thus required a nitrogen tank with nitrogen and manifold gauges to connect to the service port of the mini split to the pressurized nitrogen tank). Next, the line set needed to be vacuumed using a vacuum pump and the same manifold gauges and service port to remove the air and any contaminates (such as humidity) from the line set to confirm that the line set pressure was negative after vacuuming and was able to maintain this negative pressurization, which also acted to double check the seals for leaks. After the refrigerant line was evacuated and evaluated for leaks, the next step of attaching the communications/power wires previously required properly threading the wires through the back of the inside unit, properly connecting each wire under a designated terminal plate there, then threading the wires through the cover if the outside unit, and attaching each wire under a designated terminal plate there, remembering the color coding of the wires from the inside unit to match those of the outside unit such that the order was the same so that the unit would work correctly. This process of properly installing spade connectors to each terminal in the terminal block was time consuming, and even more laborious if the ends of the wires were bare copper without spade (or similar) connector, and if the wires in this communications/power wire bundle weren't stripped, it was extra difficult, since the copper would need to be exposed by stripping away the insulation material on each wire in this case. The next step in the process after the communications/control line installation was that of attaching the alternating current cord to the outside unit had followed a similar path: The hot, neutral, and ground wires would likely need to be stripped, threaded through the outside unit's protective cover, and property attached between the terminal plates in the connection block there for these wires. Finally, after these steps, and after the steps not related to making these connections in the installation process, the refrigerant could be released from the outside unit to the rest of the system and the system could be turned on. Optionally if the units had solar MC4 connections on the outside unit, these connections were straightforward enough to make with the solar array, but if a recommended DC isolator switch was to be attached to the solar array, it would require creating shorter male and female wires to go from the outside unit to the DC isolator, and each of those wires would need its own male and female MC4 connection. To do this, each wire needed to be stripped, then a metal male or female connector needed to be crimped on it, and finally the plastic clip part of the MC4 connector needed to be fastened to the wires and the metal connectors. This added time, effort, and money to the installation.
Previous efforts have been tried to make the installation of these systems easier, notably Lingrey et al. (US2012/0318005) for the electrical and refrigerant lines and Ingram (U.S. Pat. No. 11,125,479 B1) for the refrigerant lines. Langley has a precharged (that is, containing refrigerant at shipment) line set connected to the outside unit and requires no tools, and the user clamps the electrical, condensate lines, and refrigerant lines adjacent to the outside unit. The problem with this system is that it is notorious for leaking refrigerant, especially when the system is disconnected by unclamping. And, users may feel like they could lose a finger in the process of pushing a clamp down to make the connections, and the system can't be moved because unclamping likely causes the loss of refrigerant. Ingram also has a precharged line set, but its lines ship unconnected from both the inside and outside unit. It requires the user to have, and know-how to correctly deploy, two wrenches, either crescent or adjustable, to tighten its male and female quick connectors. Since the connectors are brass, there's a potential for cross threading. Over or under tightening are also a possibility. All of the electrical connections must be done manually. Thus, neither of these systems was foolproof for the novice installer or even a professional.
The present invention is aimed at one or more of the problems identified above.
In a first embodiment of the present invention, a partially-assembled HVAC system to be readily assembled by a user at an installation location, is provided. The HVAC system includes a first HVAC unit, a second HVAC unit, and a refrigerant line set. The first HVAC unit has a first high-pressure line stem and a first low-pressure line stem. The second HVAC unit has a second high-pressure line stem and a second low-pressure line stem. The refrigerant line set includes a high-pressure refrigerant line and a low-pressure refrigerant line.
The high-pressure refrigerant line has a first high-pressure line end and a second high-pressure line end. The low-pressure refrigerant line has a first low-pressure line end and a second low-pressure line end. The second high-pressure line end is coupled to the second high-pressure line stem such that the high-pressure refrigerant line is fluidly connected to the second HVAC unit at a pre-installation location. The second low-pressure line end is coupled to the second low-pressure line stem such that the low-pressure refrigerant line is fluidly connected to the second HVAC unit at the pre-installation location. The low-pressure refrigerant line and the high-pressure refrigerant line are connected to the second HVAC unit. The low-pressure refrigerant line and the high-pressure refrigerant line may be precharged with refrigerant at the pre-installation location. The first high pressure line end and the first low pressure line end may be coupled to the first HVAC unit by the user at the installation location.
In a second embodiment of the present invention, a method associated with a partially-assembled HVAC system is provided. The HVAC system includes a first HVAC unit, a second HVAC unit, and a refrigerant line set. The refrigerant line set includes a high-pressure refrigerant line and a low-pressure refrigerant line. The method includes the steps of at a pre-installation location, connecting the high-pressure refrigerant line to the second HVAC unit, connecting the low-pressure refrigerant line to the second HVAC unit, and pre-charging the high-pressure refrigerant line, and the low-pressure refrigerant line with refrigerant. The partially-assembled HVAC system is then shipped to an installation location. At an installation location, the method includes the steps of installing the first HVAC unit and the second HVAC unit in respective installation positions, connecting the high-pressure refrigerant line to the first HVAC unit, and connecting the low-pressure refrigerant line to the first HVAC unit.
In a third embodiment of the present invention, a partially-assembled HVAC system is provided. The partially-assembled HVAC system includes first and second HVAC units, a communications & control wire harness, a DC disconnect box, a refrigerant line set, a first high-pressure line connector, a first unit high-pressure stem connector, a first low-pressure line connector, and a first unit low-pressure stem connector. The first HVAC unit has a first high-pressure line stem and a first low-pressure line stem. The second HVAC unit has a second high-pressure line stem and a second low-pressure line stem. One of the first and second HVAC units is an indoor HVAC unit and the other one of the first and second HVAC units is an outdoor HVAC unit forming a split HVAC system configured to operate as an air-conditioner and/or heat pump. The first HVAC unit includes a terminal block. The communications & control wire harness may be preinstalled and coupled at one end to the terminal block. The communications & control wire harness may include a waterproof twist-lock connector. The DC disconnect box may be configured to be connected to DC power source(s) and to allow the HVAC system to be switched on or off from the DC power source(s). The DC disconnect box may be connected to solar panel(s) and/or battery/batteries.
The refrigerant line set includes a high-pressure refrigerant line and a low-pressure refrigerant line. The high-pressure refrigerant line has a first high-pressure line end and a second high-pressure line end. The low-pressure refrigerant line has a first low-pressure line end and a second low-pressure line end. The second high-pressure line end is coupled to the second high-pressure line stem such that the high-pressure refrigerant line is fluidly connected to the second HVAC unit at a pre-installation location. The second low-pressure line end is coupled to the second low-pressure line stem such that the low-pressure refrigerant line is fluidly connected to the second HVAC unit at the pre-installation location. The low-pressure refrigerant line and the high-pressure refrigerant line are connected to the second HVAC unit. The low-pressure refrigerant line, the high-pressure refrigerant line, and the second HVAC unit are precharged with refrigerant at the pre-installation location. The first high pressure line end and the first low pressure line end may be coupled to the first HVAC unit by the user at the installation location.
The first high-pressure line connector is connected to the first high-pressure line end of the high-pressure line. The first high-pressure stem connector is connected to the first unit high-pressure stem. The first high-pressure line connector and the first high-pressure stem connector may be self-sealing and configured to be connected by the user during installation. The first low-pressure line connector is connected to the first unit low-pressure end of the low-pressure line. The first low-pressure stem connector is connected to the first unit low-pressure stem. The first low-pressure line connector and the first low-pressure stem connector are self-sealing and configured to be connected by the user during installation at the installation location. The first high-pressure stem connector, the first high-pressure line connector, the first low-pressure stem connector, and the first low-pressure line connector are valves having an open position and a closed position.
These and other features and advantages of the present invention will become more readily appreciated when considered in connection with the following detailed description and appended drawings, wherein:
With reference to the drawings, wherein like numerals indicate like or corresponding parts throughout the several views, and in operation, the present invention relates to HVAC systems 10 and methods association with assembling HVAC systems 10. With reference to
As shown, HVAC system 10 may be powered by a solar system or solar panels 68 and/or power supplied via an electrical outlet 62 connected to the power grid. The solar panels 68 provide direct current power and the electrical outlet 62 provides alternative current power. The HVAC system 10 may include an intelligent power management system that automatically optimizes solar power over grid power thereby blending the two power sources to efficiently operate the HVAC system 10. The HVAC system 10 may also be or alternatively powered by batteries 66 that may also be charged by the solar system 68. A DC disconnect box 64 may be used to manually disconnect the solar system 68 and/or batteries 66 i.e., “turn-off”, from the HVAC system 10.
In some embodiments of the present invention, the HVAC system 10 is provided (or supplied) with AC power. DC power from the batteries and from the solar system 68 is converted to AC power using an inverter (not shown), or AC power is supplied through a traditional grid system. The AC power supplied to the HVAC system 10 is internally converted to DC power to run the motors (not shown) within the HVAC system 10. A current sensor (not shown) may be used to determine if enough current is being provided by one of the sources (the batteries 66 or the solar system 68 individually) and optimize the blend of the power supplied from the separate power sources. In these embodiments, the blend of AC and DC power may be optimized such that any extra power not needed to run the system 10 goes to the batteries. In other embodiments of the present invention, the HVAC system 10 may be supplied with DC or AC power (either from traditional grid power or supplied via an inverter) exclusively.
As discussed in more detail below, the first and second units 12, 18 are connected via a refrigerant line set 24 as well as control and power lines 70. In one aspect of the present invention, the HVAC system 10 may be partially assembled at a pre-installation location such as a factory or pre-assembly location, shipped, in the partially assembled configuration, to an installation location. The partially assembled HVAC system 10 may be installed and finally assembled at the installation location.
The HVAC system 10 is designed such that the final assembly steps may be performed by a non-professional (or “do-it-yourselfer” or “diy'er”) without special equipment. More particularly, the HVAC system 10 may be fully assembled at the pre-installation location and pre-charged with refrigerant such that the first and second units 12, 18 and refrigerant line set 24 contain refrigerant, i.e., “pre-charged”. The HVAC system 10 may then be partially disassembled and shipped in the partially assembled state to the installation location while the first and second units 12, 18 and the refrigerant line set 24 remain pre-charged.
As will be discussed in more detail below, the partially assembled HVAC 10 may then be installed at the installation location, and all final assembly steps performed by a non-professional without special tools. In particular, since the first and second units 12, 18 and the refrigerant line set 24 are pre-charged with refrigerant, the final installer does not need access to refrigerant and/or any special tools to charge the HVAC 10 with refrigerant at the installation location.
A block diagram of the components of the HVAC system 10 is shown in
The high-pressure refrigerant line 26 has a first high-pressure line end 28 and a second high-pressure line end 30. The low-pressure refrigerant line 32 has a first low-pressure line end 34 and a second low-pressure line end 36. The second high-pressure line end 30 is coupled to the second high-pressure line stem 20 such that the high-pressure refrigerant line 26 is fluidly connected to the second HVAC unit 18 at a pre-installation location. The second low-pressure line end 36 is coupled to the second low-pressure line stem 22 such that the low-pressure refrigerant line 32 is fluidly connected to the second HVAC unit 18 at the pre-installation location. The low-pressure refrigerant line 32 and the high-pressure refrigerant line 26 are thus connected to the second HVAC unit 18.
The low-pressure refrigerant line 32 and the high-pressure refrigerant line 26 may be precharged with refrigerant at the pre-installation location. The first high pressure line end 28 and the first low pressure line end 34 may be coupled to the first HVAC unit 12 by the user at the installation location.
In one aspect of the present invention, the HVAC system 10 may include a first high-pressure line connector 46, a first high-pressure stem connector 38, a first low-pressure line connector 48, and a first low-pressure stem connector 40. The first high-pressure line connector 46 is connected to the first high-pressure line end 28 of the high-pressure line 26. The first high-pressure stem connector 38 is connected to the first high-pressure stem 14. The first low-pressure line connector 48 is connected to the first low-pressure line end 34 of the low-pressure line 32.
The first low-pressure stem connector 40 is connected to the first low-pressure stem 16.
The first high-pressure line connector 46 and the first high-pressure stem connector 38 may self-sealing and configured to be connected by the user during installation. The first low-pressure line connector 48 and the first low-pressure stem connector 40 may be self-sealing and configured to be connected by the user during installation.
Each of the first high-pressure line connector 46, the first high-pressure stem connector 38, the first low-pressure line connector 48, and the first low-pressure stem connector 40 may include a valve with an off position and an on position. As will be discussed in more detail below, the first high-pressure stem connector 38 and the first high-pressure line connector 46 are paired together and may be hand-tightened together. The first high-pressure stem connector 38 and the first high-pressure line connector 46 may be configured such that the valves therein are on the open position when the first high-pressure stem connector 38 and the first high-pressure line connector 46 are connected and in the closed position when the first high-pressure stem connector 38 and the first high-pressure line connector 46 are disconnected.
Likewise, the first low-pressure stem connector 40 and the first low-pressure line connector 48 are paired together and may be hand-tightened together. The first low-pressure stem connector 40 and the first low-pressure line connector 48 may be configured such that the valves therein are on the open position when the first low-pressure stem connector 40 and the first low-pressure line connector 48 are connected and in the closed position when the first low-pressure stem connector 40 and the first low-pressure line connector 48 are disconnected.
In another aspect of the present invention, the HVAC system 10 may include a second high-pressure line connector 50, a second high-pressure stem connector 42, a second low-pressure line connector 52, and a second low-pressure stem connector 44. The second high-pressure line connector 50 is connected to the second high-pressure line end 30 of the high-pressure line 26. The second high-pressure stem connector 42 is connected to the second high-pressure stem 20. The second low-pressure line connector 52 is connected to the second low-pressure line end 36 of the low-pressure line 32. The second low-pressure stem connector 44 is connected to the second low-pressure stem 22.
The second high-pressure line connector 50 and the second high-pressure stem connector 42 may be self-sealing and configured to be connected to each other. The second low-pressure line connector 52 and the second low-pressure stem connector 44 may be self-sealing and configured to be connected to each other.
Each of the second high-pressure line connector 50, the second high-pressure stem connector 42, the second low-pressure line connector 52, and the second low-pressure stem connector 44 may include a valve with an off position and an on position. As will be discussed in more detail below, the second high-pressure stem connector 42 and the second high-pressure line connector 50 are paired together and may be hand-tightened together. The second high-pressure stem connector 42 and the second high-pressure line connector 50 may be configured such that the valves therein are on the open position when the second high-pressure stem connector 42 and the second high-pressure line connector 50 are connected and in the closed position when the second high-pressure stem connector 42 and the second high-pressure line connector 50 are disconnected.
Likewise, the second low-pressure stem connector 44 and the second low-pressure line connector 52 are paired together and may be hand-tightened together. The second low-pressure stem connector 44 and the second low-pressure line connector 52 may be configured such that the valves therein are in the open position when the second low-pressure stem connector 44 and the second low-pressure line connector 52 are connected and in the closed position when the second low-pressure stem connector 44 and the second low-pressure line connector 52 are disconnected.
In aspect of the present invention, the connectors 38, 40, 42, 44, 46, 48, 50, 52 are composed from steel or brass. As discussed in more detail below, the first HVAC unit 12 includes a terminal block 54 (
For example, the communications & control wire harness 56 may be preinstalled on the HVAC unit 12, 18 acting as the indoor unit. The other end of the communications & control wire harness 56 may include a waterproof twist-lock connector 58. Further, a power cord 60 may be connected to the HVAC unit 12, 18 acting as outdoor unit and configured to be plugged into the electrical outlet 62 to provide power to the HVAC unit 12, 18.
A DC disconnect box 64 may be provided between the DC power sources 66, 68 that acts as a switch to allow the DC power source(s) 66, 68 to be manually disconnected from the HVAC 10 for, for example, servicing purposes.
With particular reference to
Further, as described above, and in more detail below, the refrigerant line set 24 may be connected to the first and/or second HVAC units 12, 18 with self-sealing connectors 38, 40, 42, 44, 46, 48, 50, 52 that may be hand-tightened. Each end of the high-pressure refrigerant line 26 and the low-pressure refrigerant line 32 has an associated connector which may be mated with a connector at one of the first and second HVAC units 12, 18. Each mated pair of connectors 38, 40, 42, 44, 46, 48, 50, 52 may be hand-tightened. In the illustrated embodiment, each connector 38, 40, 42, 44, 46, 48, 50, 52 includes a valve (see below) having an off or closed position and an on or open position. The valves in the connectors 38, 40, 42, 44, 46, 48, 50, 52 are normally off or closed when the connectors 38, 40, 42, 44, 46, 48, 50, 52 are not connected to another connector 38, 40, 42, 44, 46, 48, 50, 52 and are on or open when connected to the mated connector 38, 40, 42, 44, 46, 48, 50, 52.
Returning to
In one embodiment of the present invention, the second HVAC unit 18 has been previously filled or precharged with refrigerant. Thus, when the low-pressure and high-pressure refrigerant lines 32, 26 are connected to the second HVAC unit 18, the refrigerant therein diffuses or enters and fills the low-pressure and high-pressure refrigerant lines 32, 26. In practice, once the refrigerant lines 32, 26 are connected to the indoor unit 12, the refrigerant lines and indoor unit 12 are vacuumed and pressure tested. Then the valves in the connectors 42, 44, 50, 52 on the outdoor unit 18 are opened to release the refrigerant. Thus, once all connections are made, the components form a refrigerant loop so that the refrigerant can flow through the loop and all components and charge the entire system 10, including the high and low-pressure lines 32, 26.
As noted above and discussed in further detail below, the low-pressure and high-pressure refrigerant lines 32, 26 and the second HVAC unit 18 may be connected by self-sealing connectors 42, 44, 50, 52 that are normally closed or off and move to the on or open position when connected.
Returning to
At the installation location, the first HVAC unit 12 and the second HVAC unit 18 are installed at respective installation positions in a fifth step S18. After the first and second HVAC units 12, 18 have been installed the high-pressure refrigerant line 26 is connected to the first HVAC unit 12 (step S20) and the low-pressure refrigerant line 32 is connected to the first HVAC unit 12 (step S22).
As noted above and discussed in further detail below, the low-pressure and high-pressure refrigerant lines 32, 26 and the first HVAC unit 12 may be connected by self-sealing connectors 38, 40, 46, 48 that are normally closed or off and move to the on or open position when connected. In another aspect of the present invention, while the HVAC system 10 is still at the pre-installation location, the refrigerant line set 24 may be (temporarily) connected to the first HVAC unit 12 via the self-sealing connectors 38, 40, 46, 48. Once connected, the self-sealing connectors 38, 40, 46, 48 are in the open position and refrigerant is allowed to flow from the second HVAC unit 18 through the refrigerant line set 24 into first HVAC unit 12 to pre-charge the first HVAC unit 12 and the refrigerant line set 24. Then, the refrigerant line set 24 may be disconnected from the first HVAC unit 12. The self-sealing connectors 38, 40, 46, 48 prevent refrigerant from exiting the first HVAC unit 12 and the refrigerant line set 24 and the HVAC system 10 is ready for shipping in a partially-assembled configuration.
In the partially assembled configuration, the refrigerant line set 24 is connected to the second HVAC unit 18 and disconnected from the first HVAC unit 12. The first HVAC unit 12, the second HVAC unit 18, and the refrigerant line set 24 are precharged (or filled) with refrigerant. After the HVAC system 10 is installed and assembled, the entire HVAC system 10 is precharged with refrigerant. Thus, none of the components of the HVAC system 10 need to be filled with refrigerant at the installation location.
As discussed above, in one embodiment of the present invention the high-pressure refrigerant line 26 has a first high-pressure line end 28 and a second high-pressure line end 30. The low-pressure refrigerant line 32 has a first low-pressure line end 34 and a second low-pressure line end 36. The second HVAC unit 18 has a second high-pressure line stem 20 and a second low-pressure line stem 22. The step (S10) of connecting the high-pressure refrigerant line 26 to the second HVAC unit 18 includes the steps of: coupling the second high-pressure line end 30 to the second high-pressure line stem 20 such that the high-pressure refrigerant line 26 is fluidly connected to the second HVAC unit 18 and coupling the second low-pressure line end 36 to the second low-pressure line stem 22 such that the low-pressure refrigerant line 32 is fluidly connected to the second HVAC unit 18.
As further discussed above, the first HVAC unit 12 has a first high-pressure line stem 14 and a first low-pressure line stem 16. A first high-pressure stem connector 38 is connected to the first high-pressure stem 14. A first high-pressure line connector 46 is connected to the first high-pressure refrigerant line end 28. The first high-pressure line connector 46 and the high-pressure stem connector 38 may be self-sealing and configured to be connected by a user during installation. A first low-pressure stem connector 40 is connected to the first low-pressure stem 16. A first low-pressure line connector 48 is connected to the first low-pressure refrigerant line end 34. The first low-pressure line connector 48 and the first low-pressure stem connector 40 may be self-sealing and configured to be connected by the user during installation. As noted above, the high-pressure line 26 and the low-pressure line 32 may also be temporarily connected to the first HVAC unit 12 at the pre-installation location using the connectors 38, 40, 46, 48. Also as discussed above, the first high-pressure stem connector 38, the first low-pressure stem connector 40, the first high-pressure line connector 46, and the first low-pressure line connector 48 may be valves having an open position and a closed position.
With reference to
In a first step S40, at the pre-installation location, the low-pressure refrigerant line 32 may be temporarily connected to the first HVAC unit 12 and in a second step S42, the high-pressure refrigerant line 26 may be temporarily connected to the first HVAC unit 12. This allows refrigerant to enter and pre-charge the first HVAC unit 12. In a third step S44, the HVAC system 10 may be operated for testing purposes. After tests are run, the low-pressure refrigerant line 32 and the high-pressure refrigerant line 26 are disconnected from the first HVAC unit 12 so the partially-assembled HVAC system 10 is ready for shipping.
As discussed above, the HVAC system includes connectors 38, 40, 46, 48. Using the connectors 38, 40, 46, 48, the steps of shown in
In the illustrated embodiment, the connectors 38, 40, 46, 48 are self-sealing and normally in the off or closed position. In other words, when the connectors 38, 40, 46, 48 are disconnected, the connectors 38, 40, 46, 48 are in the off or closed position. When the connectors 38, 40, 46, 48 connected to the opposite or mated connector 38, 40, 46, 48, each connector 38, 40, 46, 48 is automatically placed into the on or open position. Thus, the steps of connecting connectors 38, 40, 46, 48 and the step of opening the valves are combined into a single step.
In one embodiment, each stem connector 38, 40, 42, 44 forms a pair of connectors with an associated line connector 46, 48, 50, 52. The first high-pressure stem connector 38 is paired or mated with the first high-pressure line connector 46; the first low-pressure stem connector 40 is paired or mated with the first low-pressure line connector 48; the second high-pressure stem connector 42 is paired or mated with the second high-pressure line connector 50; and the second low-pressure stem connector 44 is paired or mated with the second low-pressure line connector 52.
With reference to
With specific reference to
As shown, the female self-sealing connector 72 includes a fixed-position rod 74 having a rod head 76. The rod head 76 is surrounded by a cylinder-shaped plunger or female outer sleeve 78. The female outer sleeve 78 is pushed forward (away from the second end 72A of the female self-sealing connector 72) to be in line with the rod head 76 by a first spring 80 when not connected to a male self-sealing connector. The female outer sleeve 78 is thickest near the female rod head 76 which defines an interface between the female and male self-sealing connectors 72, 100. The cylinder-shaped female outer sleeve 78 is surrounded by a female outer shell 84. Directly behind and in line with the female rod head 76 is a female inner sleeve 86 that acts as a second plunger. The female inner sleeve 86 is pushed forward (towards the female rod head 76) by a second spring 82 when the female self-sealing connector 72 is not connected to a male self-sealing connector 100. The female inner sleeve 86 includes a female inner shell ridge 88 distal from the female rod head 76. As shown, the female outer shell 84 is threaded 90.
With specific reference to
The male self-sealing connector 100 has an inner cap plunger 102, a fixed-position rod 113, a male outer sleeve 104, and a rotating outer bezel 105. The inner cap plunger 102 is pushed or biased forward towards the second end 100B by a spring 106 when the male self-sealing connector 100 is not connected to a female self-sealing connector 72. The male outer sleeve 104 has a fixed position and is surrounded by a male outer shell 108. The male outer sleeve 104 and the rotating outer bezel 105 define a cavity 110 near the second end 100B which defines the interface point between the male and female self-sealing connectors 72, 100. Further into the male self-sealing connector 100, there is no cavity, and the male outer sleeve 104 is directly adjacent to the male outer shell 108. An inner surface of the outer bezel 105 is threaded 112.
When the male self-sealing connector 100 interfaces with the female self-sealing connector 72, the threads 90 on the outside female outer shell 84 attached or interface with the threads 112 on the outer bezel 105 as the outer bezel 105 is rotated clockwise. As the outer bezel 105, the fixed-position female rod head 76 of the female fixed-position rod 74 pushes against the inner cap plunger 102 of the male self-sealing connector 100 acting against the force applied to the inner cap plunger 102 by the spring 106. This creates a passage 120 (see
Refrigerant can flow through the created passageways 120 when the male and female self-sealing connectors 100, 72 are fully connected. Refrigerant is prevented from flowing through the male and female self-sealing connectors 100, 72 when disconnected.
At the time when the passage 120 is formed, the female outer sleeve 78 pushes down or against, the first spring 80 when the bottom of the female outer sleeve 78 reaches the first spring 80. When the female inner shell ridge 88 makes contact with a thick part of the female outer sleeve 78, the female inner sleeve 86 pushes down on the second spring 80.
When the rotating bezel 105 is unscrewed from the female outer shell 84, the spring 106 in the male self-sealing connector 100 pushes the inner cap plunger 102 to the closed position or beginning position and the first and second springs 80, 82 in the female self-sealing connector 72 push the female inner and outer sleeves 86, 78 forward until a ridge 92 on the female outer sleeve 78 abuts a ridge 94 on the inside of the female outer shell 84, at which time the components of the female self-sealing connector 72 are all back to their beginning or closed position.
In one embodiment, there may be male self-sealing connectors 100 on each refrigerant line 26, 32 coming from the second or outside unit 18 corresponding to female self-sealing connectors 72 on each of the line stems 14, 16 coming from the first or inside unit 12. Or, there may be female self-sealing connectors 72 on each refrigerant line 26, 32 coming from the second or outside unit 18 corresponding to male self-sealing connectors 100 on each line stem 14, 16 coming from the first or inside unit 12. Or, there may be a male self-sealing connector 100 on the low-pressure refrigerant line 32 from the second or outside unit 18 corresponding to a female self-sealing connector 72 on the low-pressure stem 16 from the first or inside unit 12, along with a female self-sealing connector 72 on the high-pressure line 26 from the second or outside unit 18 corresponding to a male self-sealing connector 100 on the high-pressure stem from the first or inside unit 12. Finally, there may be a female self-sealing connector 72 on the low-pressure line 32 from the second or outside unit 18 corresponding to a male self-sealing connector 100 on the low-pressure stem 16 from the first or inside unit 12, along with a male self-sealing connector 100 on the high-pressure line 26 from the second or outside unit 18 corresponding to a female self-sealing connector 72 on the high-pressure stem 14 from the first or inside unit 12.
Returning to
As shown, in
The first end 72A of the female self-sealing connector 72 is include an adapter 96 configured to connect the female self-sealing connector 72 to the refrigerant line or stem (as appropriate). In the illustrated embodiment, the adapter 96 is a male end (with normal pipe threads) connected to the first end 72A and a female flared end (as shown in
In other embodiments, the self-sealing connectors 72, 100 may be connected directly to the refrigerant line or stem (as appropriate).
The rear ends (defined by the first ends 72A, 100A of the connectors 72, 100 have normal pipe threads and are installed using nut drivers. A sealant between the threads may be used.
With reference to the drawings, wherein like numerals indicate like or corresponding parts throughout the several views, and in operation, the present invention relates to HVAC systems 10 and methods association with assembling HVAC systems 10. The HVAC system 10 may include a first unit 12 and a second unit 18. The HVAC system 10 is a split system, i.e., one of the first and second units 12, 18 is an indoor unit and the other is an outdoor unit. In the illustrated embodiment, the first unit 12 is the indoor unit and the second unit 18 is the outdoor unit.
In one aspect of the present invention, a refrigerant line set 24 connects the first and second HVAC units 12, 18. The refrigerant line set 24 includes a high-pressure refrigerant line 26 and a low-pressure refrigerant line 32. The refrigerant line set 24 is preinstalled on one of the HVAC units 12, 18, for example, the outside unit, of the split system and is precharged with refrigerant prior to the partially-assembled HVAC system 10 being delivered to the final installer (likely the end user) at the installation location. In this example discussed below, the refrigerant line set 24 is connected to the outside unit 18 during shipping. The refrigerant line set 24 is disconnected from the indoor unit 12. However, it should be noted that in other embodiments, the refrigerant line set 24 may be connected to the indoor unit 12 and disconnected from the outside unit 18 during shipping to the installation or distribution site.
At least one end of each of the high-pressure refrigerant line 26 and the low-pressure refrigerant line 32 which is to be connected to the inside unit 12 has a self-sealing connector 72, 100, e.g., a female self-sealing connector 72, which keeps the refrigerant from leaking out before installation. The inside unit 12 and line stems 14, 16 are also precharged with refrigerant. The line stems 14, 15 are terminated with male self-sealing connectors 100. The male self-sealing connector 100 is screwed onto the female self-sealing connector 72 by hand which allows for refrigerant to flow between the inside and outside units 12, 18 of the split system 100. In an alternate configuration, one low-pressure line connector 48 may be a male self-sealing connector 100 to adjoin with a female self-sealing connector 72 as the low-pressure stem connector 40, and one high-pressure line connector 46 may be a female self-sealing connector 72 to connect with a male seal sealing connector 100 as the high-pressure stem connector 38. Or, in another alternate configuration, one low-pressure line connector 48 may be a female self-sealing connector 72 to adjoin with a male self-sealing connector 100 as the high-pressure stem connector 38, and one high-pressure line connector 46 may be a male self-sealing connector 100 to connect with a female self-sealing connector 72 as the high-pressure stem connector 38. The advantage of these two alternate configurations is that it will avoid errors of the installer at the installation site connecting different-sized lines together erroneously.
The self-sealing connectors 38, 40, 42, 44, 46, 48, 50, 52, 72, 100 may be composed from steel to reduce or eliminate cross-threading. Alternatively, the self-sealing connectors 38, 40, 42, 44, 46, 48, 50, 52, 72, 100 may be composed from brass.
Since the line set 24 is shipped to the end user at the installation location with refrigerant already installed (and at the correct pressure), there is no need to vacuum out the air and other debris, normally a requirement before releasing the refrigerant to HVAC systems to avoid contamination of the refrigerant. The connectors 38, 40, 42, 44, 46, 48, 50, 52, 72, 100 are configured to eliminate refrigerant leaks when shipped, disconnected, or reconnected. Thus, the HVAC system 10 may be moved and even be made portable. Optional additional line set extender pieces (not shown) can be provided and attached this same quick way, without the need of brazing one piece of line set to the other as the user would normally need to do if and when adding length to an existing line set. The extender pieces are precharged with refrigerant with self-sealing connectors 72, 100 at each end thereof.
Similarly, the connections for the communications and control wire harness 56 from the inside unit 12 to the outside unit 18 may also be made by hand, i.e., without tools. The communications and control wire harness 56 (see
The alternating power connection, i.e., power cord 60 may preinstalled on the outside unit after the power cord 60 has been threaded through the cover plate 114 of the outside unit 18. A protective cap 118 may protect the female part 122B of the twist connector 122 when the inside unit 12 and the outside unit 18 are not connected with the control wire harness 56, i.e., when the system 10 is not in use).
If the split HVAC system 10 is to offer, and have, solar panels or array, i.e., solar system 68 attached thereto, the DC disconnect box 64 (also known as an isolator) may be preinstalled or temporarily installed onto the outside unit 18 using solar wires with male and female MC4 connector 128A, 128B, 130A, 130B attached at both ends. The solar wires are plugged into its corresponding connectors on both the outside unit 18 and the DC disconnect box 64. In this way, the user can simply attach the solar array 68 to the other side of the DC disconnect box 64.
The HVAC system 10 of the present invention allows a true do-it-yourself option for individuals who neither have the equipment nor the training to install or uninstall (and potentially reinstall) a split system (with or without solar). Alternatively, the HVAC system 10 of the present invention will allow those who have the tools and expertise to forgo the time previously required before this invention.
Generally, the HVAC system 10 of the present invention does not require wrenches and the expertise to use them. The self-sealing connectors 38, 40, 42, 44, 46, 48, 50, 52, 72, 100 may normally be installed at just one location (such as on the high-pressure and low-pressure lines at the inside unit). The self-sealing adapters 38, 40, 42, 44, 46, 48, 50, 52, 72, 100 are composed from steel to reduce or eliminate the risk of cross-threading. Additionally, the HVAC system 10 may also come with alternating current wires, communications/control wires, and solar wires preconnected which saves the installer time, effort, and money in the installation and disconnecting process.
As discussed above, the HVAC system 10 may be temporarily assembled at the pre-installation location. In other words, both ends of the high-pressure refrigerant line 26 and the low-pressure refrigerant line 34 are connected to the indoor unit 12 and the outdoor unit 18. Once connected, the refrigerant line set 24 may now be nitrogen tested, vacuumed via a service port (not shown), and refrigerant released by opening the refrigerant valves (not shown) on the outside unit 18, in the same manner as would be on a standard split system during the installation process, except that the units 12, 18 of the present invention will be only connected in a temporary staging area at the pre-installation location for the purpose of filling the line set 24 and the inside unit 18 with the proper amount of refrigerant. As such, the line set 24 is not run through a wall and the inside unit 18 is not mounted on a wall as they will be at the installation location.
At the pre-installation location, once all connections have been made and refrigerant released throughout the HVAC system 10, the HVAC system 10 can be powered on and run until it reaches a normal operating pressure (for testing purposes).
At the end of this testing process, the refrigerant lines 26, 34 and the indoor and outside units 12, 18 are charged or pre-charged with refrigerant, the refrigerant lines 26, 34 may be disconnected at the connection point by unscrewing the male self-sealing connectors 100 from the respective female self-sealing connectors 72. Once disconnected, the valves within the connectors 72, 100 close where refrigerant-resistant O rings and/or the springs 80, 82, 106 maintain the seal and prevent refrigerant from leaking out and ambient air and other contaminates from leaking in.
As such, the refrigerant line set 24 remains connected to the outside unit 18 on one end and unconnected at the other end. The refrigerant line set 24 and the connectors 72, 100 may be cooled and shipped together with the outside unit 18. The inside unit 12 may be shipped with connectors 72, 100 connected to the line stems 14, 16.
An additional alternative precautionary step is to also close the refrigerant valves (not shown) which would help keep much or most of the refrigerant in the outside unit 18 if either refrigerant line 26, 32 cracked or otherwise became damaged during shipping.
At the installation location, the end user can easily install the system 10 either permanently or temporarily. For current split systems, including mini split system, the user normally installs the inside unit on a wall which has one side facing inside (such as into a living room or bedroom), and one ground or L-bracket mounted outside (such as facing their backyard). To connect the inside unit 12 and the outside 18 unit, an aperture through the exterior wall at the chosen location for the inside unit 12, and then either guiding the line set 24 with the female connectors 72 from the outside unit 18 through the aperture in the wall and then the connectors 72, 100 may be reconnected in the same manner described above. Alternatively, the refrigerant line set 24 may be shipped connected to the inside unit 12. It should be noted, in one aspect of the present invention, each end of the line set 24 may have one female self-sealing connector 72 and one male self-sealing connector 100. Since the refrigerant lines may be of different sizes, this makes the installation foolproof by preventing the user from misconnecting the refrigerant lines 26, 32.
Optionally, the user can order an extender line set (not shown) which allows the inside unit 12 and outside unit 18 to be further apart. This may come in handy for the user if, for instance, they assumed that the line set 24 ordered with the HVAC system 10 was enough to connect the two units 12, 18, but in fact they needed extra line set to make this connection because of the final distance apart of the inside unit 12 and outside unit 18. The extender set has one male connector 100 at one end and a female connector 72 at the opposite end. As such, the male connector 100 may be attached to the free end of the line set 24 coming from the outside unit 18 which terminates with a female connector 72. The extender can be connected at the pre-installation location and pre-charged along with the original refrigerant line set and shipped connected to the refrigerant line set 24. Alternatively, a longer line set 24 may be preinstalled with the correct connectors 72, 100 at the assembly location based on the end user's requirements.
In one embodiment, self-sealing connectors 72, 100 are provided only at one end of the refrigerant line set. Thus, the refrigerant line set 24 is fixedly connected to the outside unit 18 and removably connected (using the self-sealing connectors 72, 100) to the inside unit 12.
Alternatively, the connection at the inside unit 12 and the outside unit 18 can be reversed. In other words, the self-sealing connectors 72, 100 may be installed at the outside unit 18 and the refrigerant line set 24 may be fixedly connected to the inside unit 12.
In another embodiment, both ends of the refrigerant line set 24 are coupled to the indoor unit 12 and the outside unit 18 using self-sealing connectors 72, 100.
In one embodiment, the communications & control wire harness or cable 56 contains 3 wires used for the inside unit 12 to communicate with the outside unit 18, plus a ground wire which allows the inside unit 12 to be grounded back to the outside unit 18. The wires are connected in the traditional way on the inside unit 12 at the initial assembly. That is, the communications & control wire harness 56 is threaded through the back of the inside unit 12 such that it is visible under the cover of the inside unit 12, and the wires are then pulled up and connected to the terminal block 54 on the inside unit 12. The wires on the other end of the communications & control wire harness 56 are connected to the back side of the male twist connector part 122A. Meanwhile, on the outside unit 18, wires of the same color and in the same order (e.g., pin 1=black, pin 2=blue, pin 3=brown, pin 4=green) as the on the male twist connector part 122A and in the same order and same color configuration as on an inside unit terminal block are attached to the back side of the female twist connector part 122B.
The wires contained from the back side of the female twist connector part 122B are relative, for example, only a few inches. These wires may be bundled in a short, insulated cable, or they may just be individual wires. These wires are threaded through a waterproof flange of the cover plate 114 through the front of the cover plate 114 and connected to the terminal block 55 on the outside unit 18. Once that's done, the female twist connector part 122B is fastened to the cover plate 114. This is accomplished by screwing four screws, or possibly bolts, through the female twist connector part 122B and the cover plate 114 to hold it in place and create a waterproof seal so no water can get into the outside unit 18 or into the female twist connector part 122B.
Finally, to make the communications/power connection from the inside unit 12 to the outside unit 18, the communications & control wire harness 56 must be connected to the internal wires. To do this, the male twist connector part 122A must be twisted onto the female twist connector part 122B The male twist connector part's 122A male connection pins must be inserted into the female twist connector's 122B female connection pin sockets. The order of the pins is important, and as such, the male protruding pins must be lined up with their corresponding female sockets. The housing for connector parts 122A, 122B may have plastic tabs and grooves to make this process foolproof, Once lined up, the installer pushes the male twist connector part 122A and twists clockwise, making use of a male twist connector catch and female twist connector threads, until twist connector 122 locks into place, at which point the connection has been made in the proper sequence and the connector parts 122A, 122B form a watertight seal. To further aid in ensuring the accuracy of the installation, one of the male pins may be longer, and one female pin socket may be longer such that the longer pin will only fit this socket. The HVAC system 100 may be tested provided other necessary connections in the system 100 have been made after which time the communications & control wire harness 56 have completed their initial assembly and are ready for shipment.
Prior to shipment from the pre-installation location to the installation location (after testing has been completed, the connectors 122 may be disconnected by simply twisting the male connector part 122A counterclockwise to release the male connector part 122A from the female connector part 122B. The communications & control wire harness 56 for the inside unit 12 is packed with the inside unit 12 and remains connected to the terminal block 54 of the inside unit 12. The female connector part 122B may protected during shipping by the optional protective cap 118. The protective cap 118 may be tethered to the outside unit to prevent loss thereof.
At the installation location, the end user reconnects the inside unit 12 and the outside unit 18 by normally threading the communications & control wire harness 56 from the inside unit 12 through a hole in the wall, and attaching the communications & control wire harness 56 to the outside unit 18 by first lining up the male protruding pins, as well as the tabs on the male connector part 122A with the grooves on the female connector part 122B, with their corresponding female recesses slots and simply pushing in while twisting the male twist connector part 122A onto the female twist connector part 122B until the male twist connector part 122A cannot be twisted anymore.
The inside unit 12 and outside unit 18 may also be connected in a manner such that a hole in the wall or through the roof with a roof jack is not necessary. For instance, all connections, including the communications & control wire harness 56 from the inside unit 12 to the outside unit 18 can be done under a garage door. To move the inside unit 12 and outside unit 18, all connections between the units 12, 18 must be undone. So, the communications & control wire harness 56 can be disconnected by the male twist connector part 122A being twisted counterclockwise to release it from the female twist connector part 122B as described above in the initial assembly and preparation of the communications/control wires before shipping to the end user (or distributor) section.
Alternatively, the configuration can be reversed such that the female twist connector 122B and associated hardware, including the wire harness 56, are connected to a terminal bock at the inside unit 12, and the communications & control wire harness 56 is fed to the cover plate 114 on the outside unit 18 and the male twist connector part 122A is wired to the terminal block 55 of the outside unit 18. The communications & control wire harness 56 may have the female twist connector part 122A to attach to the male twist connector 122B at the outside unit 18.
The alternating current cable or power cord 60 are threaded through the cover plate 114 of the outside unit 18 and attached to corresponding terminals on an alternating current terminal block (not shown). A seal may be put around the gap area between the power cord 60 and the edge of associated aperture on the cover plate 114 through which the power cord 60 passes. When all other required connections for the unit are also made, the plug end of the power cord 60 can be plugged into a live wall outlet or live extension cord to make sure the outside unit powers up correctly with alternating current power.
For shipping, the power cord 60 is simply unplugged and consolidated with a twist tie or similar band to keep the power cord 60 stable and near the outside unit 18. As such, the power cord 60 can likely be shipped in the same original box of the outside unit 18.
For reconnecting the outside unit 18, the power cord 60 may be simply plugged the power outlet 62 with correct current and voltage available by the end user. If the user would like to move the outside unit 18, the outside unit may be simply unplugged and plugged into a new location with correct power available.
If the HVAC system 10 is to be used with a solar system 68, the solar system 68 may be connected to the outside unit 18 via the optional solar DC disconnect box 64. With specific reference to
The solar connectors 124 may be connected to the DC disconnect box 64 via a solar wire harness 126 (see
The positive wire 128 may be removably attached to the male prewired MC4 connector 124A of the outside unit 18 by attaching the female MC4 connector 128B thereto. The positive wire 128 passes through one of the holes on the cover plate 114. Next, the positive wire 128 attaches to the solar disconnect box (or solar isolator switch) 64 via the male MC4 connector 128A attaching to a female bottom connector of the disconnect box 64. Meanwhile, the negative wire 140 is attached to the outside unit 18 by passing through one of the apertures in the cover plate 114 to connect the male MC4 connector 130A to the female prewired connector 124B on the outside unit 18. The female MC4 connector 130B attaches to the bottom male MC4 connector on the disconnect box 64. If all other necessary connections are made between the inside unit 12 and outside unit 18, and if the appropriate-sized solar array 68 is properly attached to the disconnect box 108 (and there is sufficient sunlight hitting the solar array 68), the disconnect box 64 may be turned on to test the solar connections.
To prepare the system 10 for shipping after initial assembly and preparation for shipping of the solar wires before shipping to the end user (or distributor), the disconnect box 64 must be turned to the ‘off’ position, and the solar array 68 needs to be disconnected from the top disconnect box 64. The solar wire harness 126 may stay attached to the disconnect box 64 and to the outside unit 18 and shipped therewith. Alternatively, the solar wire harness 126 can be disconnected from the outside unit 12 and ship separately while still connected to the disconnect box 64 or still connected to the outside unit 18.
When the user receives the partially-assembled HVAC system 100, after making all other necessary connections between the inside unit 12 and the outside unit 18, the user then can attach their (if not provided) solar array to the MC4 connectors (not shown) on the disconnect box 64, and turn the disconnect box 64 to the ‘on’ position. Alternatively, if the disconnect box 64 and the solar wire harness 126 ship separately, the solar wire harness 126 needs to be reconnected by the user to the outside unit 18. Then the user may attach the solar array to the disconnect box 64 (typically using MC4 connectors) and turn the disconnect box 64 to the ‘on’ position.
To move the outside unit 18, the user turns the disconnect box 64 to the ‘off’ position, makes all other necessary disconnections between the inside unit 12 and the outside 18, and disconnects the solar array 68 from the disconnect box 64. To move the outside unit 18 in the alternative case, the disconnect box 64 is turned ‘off,’ the solar array 68 is disconnected, all other non-solar connections between the inside unit 12 and the outside unit 118 are disconnected, and the solar wire harness 126 can remain connected to the outside unit 18 as in the first case, or, if easier, the solar wire harness 126 can be disconnected from the outside unit 18, whichever is easier for the user.
Optionally, solar panels 68 (which are likely compact and/or foldable and/or lightweight) can be attached to the disconnect box 64 (using MC4 connectors) and shipped with the rest of the system 10. These optional solar panels 68 can be connected, tested, shipped (without being disconnected), disconnected (if desired) by the end user when deciding on a mounting position for them, then reconnected by the end user for use.
No tools are required to connect the refrigerant lines 24 running from the inside unit 12 to the outside unit 18. The self-sealing connectors 72, 100 may be simply hand-tightened together at the inside unit 12. As such, the installer only needs to connect the line set at the inside unit. The line set is already preinstalled at the outside unit. As discussed above, in alternative embodiments, the location of the self-sealing connectors 72, 100 may be reversed, located at the outside unit 18, or at both units 12, 18.
The correct amount of refrigerant is precharged in the inside unit 12, in its line stems 14, 16, in the outside unit 18, and in its line set 20, 22, 2632. In this context, the term precharged means that these elements contain the correct amount of refrigerant before shipping. The final installer does not need to test the lines or add refrigerant to the components or the rest of the system.
Further, the foolproof self-sealing steel connectors (of some embodiments) cannot be cross threaded, which is a common problem for brass connectors.
An optional extender line set terminating with one male and one female self-sealing connector can be added to the current line set described above if the installer finds that the single line set described above is not long enough to reach from the inside unit to the outside unit. This extender line set does not require an additional adapter between it and the original line set. Multiple extender line sets can be added to the original line or to another adapter. And again, the extender line set(s) is/are hand tightened to the original self-sealing line set-no tools are needed. The extender line sets also already contain the correct amount of refrigerant when they are received by the installer.
The communications & control wire harness 56 between the inside and the outside units can be connected by hand without tools. One end of the communications & control wire harness 56 may be preinstalled on the inside unit 12 connection points on the terminal block 54 of the inside unit 12, and the other end has a preinstalled male (or female) waterproof twist-lock connector (see above). Short connections are made from connection points of the outside unit 18 to a female (or male) waterproof twist-lock connector (see above) which bridges the front and back of the cover plate 114 of the outside unit 18 such that the backside of the female connector 122B is inside of the outside unit 18, and the front side which interfaces with its male counterpart is on the outside of the outside unit 18.
The outside unit 18 has a preinstalled power cord 60 such that the hot, neutral, and ground wires terminate in the hot, neutral, and ground stripped ends on one end of the power cord 60. The power cord 60 then passes through the cover plate 114 and the hot, neutral, and ground wires are connected to the outside unit terminal block's hot, neutral and ground points for alternating current. As such, the end user just plugs the outside unit 18 into a 110-120 v North American outlet using the power outlet 62.
Alternatively, the outside unit 18 may have a preinstalled power cord 60 such that the two hots and ground wires terminate in the two hots and ground stripped ends (or spade connectors or other easy connectors) on one of the power cord 60. The power cord 60 then passes through the cover plate 114 and the two hots and ground wires are connected to the terminal block 55 of the outside unit 18.
In either case, no tools are needed for the end installer to connect the system 10 to the building's alternating current power since the cable has been prewired to the system 10 and since the other end of the cable terminates with a plug end.
Since the alternating current connection, direct current connection, line set connection, and optional photovoltaic connection are all made by hand, the only tools needed for the installation of the system 10 at the installation location are a standard drill, a level, a Phillips screw bit, 2 standard drill bits, and a hole saw. The system 10 may ship with the level, Phillips screw bit, 2 standard drill bits, and the hole saw, so the only tool the end installer must have is a standard drill.
Since all of the connections are done by hand, and since all of these connections, including the line set, can be disconnected and reconnected multiple times, the units 12, 18 is movable and could possibly be deemed to be portable.
Users could potentially create a docking station at, say, a summer cabin where only a wall bracket or a more-temporary method for holding up the inside unit could be employed.
In the future, the inside unit 12 could be fashioned to be more in the shape of a floor fan such that the line set 24 could possibly be slid under, say, a garage door, and no wall bracket or wall hole would be needed for the inside unit.
The system 10 is plug-and-play ready to run with a solar system or solar panels (or an array) 68.
The solar panel array 68 may directly connected to the outside unit 18 using preinstalled MC4 connectors on the outside unit 18 (see above). The internal motors used by the system 10 all run on DC power. As such, no batteries, external voltage regulators, or inverters are needed. Optionally, a disconnect box/DC isolator switch 64 may be connected between the array 68 and the outside unit 18.
In one aspect of the present invention, the system 10 automatically uses solar before grid power. Grid power is only used when it's cloudy or at nighttime. Examples: It's very sunny, and there's enough solar power to run the system . . . no grid power is used. Example: It's a bit cloudy, and there's not enough solar power to run the system . . . all of the available solar is used, and any extra power needed comes from the grid. Example: It's nighttime . . . all of the power comes from the grid.
Foldable and/or flexible solar panels 68 may be directly connected to the outside unit 18 or the DC isolator switch 64 as described above before the system 10 is initially shipped.
An optional battery array 66 may be attached to the system 10. The battery array 66 may allow any solar power unused by the system 10 to flow to the batteries 66 to allow it to be stored. Example: It's 75 degrees fahrenheit outside, and there's not much of a heating or cooling load, so the solar panels 68 produce extra power not used for running the system 10. As such, this power can be stored onsite in batteries. This battery storage system 66 may allow storage only when there's no load at all for the system 10. In this case, all of the solar power may flow to batteries 66. The battery storage system 66 may allow storage even when there's a partial load at the system 10. In this case, some of the solar power may flow to the batteries 66. This battery storage system 66 may feed only an inverter (not shown) to supply power to other devices besides the system 10. And/or, the batteries 66 may feed only back into the system 10. The storage system may feed both back into the system 10 and into an inverter (not shown) to supply other devices besides the system 10.
If the inverter supplies the same alternating current needed by the system 10, the system 10 may be plugged into the inverter to run the system 10. Example: The output of the inverter is 110 v alternating current power. The system 10 runs on 110 v alternating current power. As such, the outside unit's 18 alternating current power plug could be plugged into the inverter to power the system 10 when there isn't sufficient solar power to power the system 10 partially or entirely.
The foregoing invention has been described in accordance with the relevant legal standards, thus the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and fall within the scope of the invention.
This application claims priority to U.S. Provisional Patent Application Ser. No. 63/500,958, filed on May 9, 2023 (Attorney Docket AIRSPOOL-P0001P) and U.S. Provisional Patent Application Ser. No. 63/581,291, filed on Sep. 8, 2023 (Attorney Docket Number AIRSPOOL-P0002P), the entire disclosures of which are hereby incorporated by reference and relied upon.
| Number | Date | Country | |
|---|---|---|---|
| 63581291 | Sep 2023 | US | |
| 63500958 | May 2023 | US |
