The present invention is generally directed to a HVAC (Heating, Ventilating, and Air Conditioning) system. More specifically, the present invention is directed to an HVAC system with a single piece body.
An air conditioning system typically includes an evaporator coil, a condenser, an accumulator, a condenser, and a metering device. The components are interconnected by pipes or tubing, and separate fans move air across the evaporator coil and the condenser. A refrigerant is in various phases as it flows through the air conditioning components. Circulating refrigerant vapor enters the compressor and is compressed to a higher pressure, resulting in a higher temperature as well. The compressed refrigerant vapor is now at a temperature and pressure at which it can be condensed and is routed through the condenser. In the condenser, the compressed refrigerant vapor flows through condenser coils. A condenser fan blows air across the condenser coils thereby transferring heat from the compressed refrigerant vapor to the flowing air. Cooling the compressed refrigerant vapor condenses the vapor into a liquid. The condensed refrigerant liquid is output from the condenser to the accumulator where the condensed refrigerant liquid is pressurized. The condensed and pressurized refrigerant liquid is output from the accumulator and routed through the metering device where it undergoes an abrupt reduction in pressure. That pressure reduction results in flash evaporation of a part of the liquid refrigerant, lowering its temperature. The cold refrigerant liquid/vapor is then routed through the evaporator coil. The result is a mixture of liquid and vapor at a lower temperature and pressure. The cold refrigerant liquid-vapor mixture flows through the evaporator coil and is completely vaporized by cooling the surface of the evaporator coil and cooling air moving across the evaporator coil surface. The resulting refrigerant vapor returns to the compressor to complete the cycle.
In a single family unit, certain components of the air conditioning system are located inside the house and other components are located outside, for example the condenser and condenser fan are located outside the house and the remaining components are located inside. Typically, the inside components are co-located with the furnace, related air moving components, and air ducts associated with the house's HVAC system. However, in multi family units, such as apartment or condominium complexes, separate positioning of the air conditioning components both inside and outside of each unit is not always feasible. Integrated, box-like, air conditioning units are often used. Such units can be mounted in windows or custom sized wall openings, with a portion of the unit extending into the living area and another portion extending outside beyond an outer wall of the dwelling.
Embodiments are directed to an HVAC system that includes a front side access panel, an HVAC unit, a mounting sleeve, and a back side grille. The mounting sleeve and the HVAC unit are configured to fit within the preexisting framing of a building, and in particular to be mounted in a wall, between pre-existing studs, of a room. The HVAC unit can be installed into the mounting sleeve via quick connect mechanisms including, but not limited to, snap in connections and/or tab and slot features. The mounting sleeve enables rapid installation and also condensate collection. The HVAC unit includes an evaporator section, a mechanical section, and a condenser section that are integrally formed as a single physical unit. The design of the HVAC system is optimized to maximize space utilization and support efficient installation and servicing while minimizing product intrusion into living space. The HVAC system includes vertically oriented HVAC components and component connections that are self-aligned. In some embodiments, the HVAC system can be further configured with a horizontal configuration portion for multi-zone capability.
In an aspect, a heating, ventilation, and air condition (HVAC) system is disclosed. The HVAC system includes an HVAC unit and a mounting sleeve. The HVAC unit comprises an evaporator section having a first heat exchanger, a mechanical section having an HVAC unit controller, and a condenser section having a second heat exchanger. The evaporator section, the mechanical section, and the condenser section are integrated as a single unit. The mounting sleeve configured to fit within a preexisting framework of a dwelling. In some embodiments, the HVAC system further comprises a front side access panel coupled to a front side of the HVAC unit. In some embodiments, the front side access panel comprises a front side grille aligned with the evaporator section. In some embodiments, the HVAC system further comprises a back side grille coupled to a back side of the HVAC unit. In some embodiments, the mounting sleeve includes a back side opening in a back side wall, the back side opening is aligned with the condenser section of the HVAC unit and an exterior opening of the dwelling, further wherein the back side grille is positioned over back side opening. In some embodiments, the mounting sleeve comprises a back side wall, side walls, a top wall and a bottom wall, wherein the back side wall is mounted to a framing back side wall of the preexisting framework, and each of the side walls is mounted to a stud of the preexisting framework. In some embodiments, one or more of the side walls of the mounting sleeve includes an electrical outlet opening. In some embodiments, the mechanical section further comprises an electrical power cord, a first end of which is configured to fit through the electrical outlet opening. In some embodiments, the mounting sleeve comprises a bottom side wall that is sloped downward from a front side of the HVAC unit to a back side of the HVAC unit. In some embodiments, the bottom side wall comprises one or more drainage openings. In some embodiments, the mounting sleeve further comprises a back side wall having one or more drainage openings proximate the bottom side wall. In some embodiments, the HVAC unit further comprises interconnecting refrigerant tubing coupled to the evaporator section, the mechanical section, and the condenser section. In some embodiments, the HVAC unit further comprises first mounting features and the mounting sleeve further comprises second mounting features for mounting to the first mounting features. In some embodiments, the first heat exchanger of the evaporator section comprises an evaporator coil, and the evaporator section further comprises an air mover configured to move air across the evaporator coil. In some embodiments, the second heat exchanger of the condenser section comprises a condenser coil, and the condenser section further comprises an air mover configured to move air across the condenser coil. In some embodiments, the condenser section further comprises an accumulator coupled to the condenser coil. In some embodiments, the mechanical section further comprises a compressor and a metering device.
Several example embodiments are described with reference to the drawings, wherein like components are provided with like reference numerals. The example embodiments are intended to illustrate, but not to limit, the invention. The drawings include the following figures:
Embodiments of the present application are directed to an HVAC system. Those of ordinary skill in the art will realize that the following detailed description of the HVAC system is illustrative only and is not intended to be in any way limiting. Other embodiments of the HVAC system will readily suggest themselves to such skilled persons having the benefit of this disclosure.
Reference will now be made in detail to implementations of the HVAC system as illustrated in the accompanying drawings. The same reference indicators will be used throughout the drawings and the following detailed description to refer to the same or like parts. In the interest of clarity, not all of the routine features of the implementations described herein are shown and described. It will, of course, be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made in order to achieve the developer's specific goals, such as compliance with application and business related constraints, and that these specific goals will vary from one implementation to another and from one developer to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking of engineering for those of ordinary skill in the art having the benefit of this disclosure.
An air mover 30 in the evaporator section 4 is coupled to the heat exchanger 32 to blow air over the evaporator coil, and an air mover 46 in the condenser section 8 is coupled to the heat exchanger 48 to blow air over the condenser coil. A compressor controller 36 is coupled to the compressor 38. An HVAC unit controller 34 is coupled to the air mover 30, the compressor controller 36, the one or more valves such as valves 40, the metering device 44, and the air mover 46. Control signaling, indicated by “C” in
In some embodiments, air filters are included as part of the evaporator section 4 and the condenser section 8. Air is drawn into the evaporator section 4, such as from the room in which the HVAC is installed, directed across the evaporator coil, and output from the evaporator section 4 back into the room. The air filter can be positioned at an air intake portion of the evaporator section 4 such that air is filtered prior to being blown across the evaporator coil. Similarly, air is drawn into the condenser section 8, such as from outside the dwelling within which the HVAC is installed, directed across the condenser coil, and output from the condenser section 8 back outside the dwelling. The air filter can be positioned at an air intake portion of the condenser section 8 such that air is filtered prior to being blown across the condenser coil.
In some embodiments, the HVAC unit is an integrated single unit that includes the evaporator section, the mechanical section, and the condenser section integrated as a single piece body. The single piece HVAC unit is mounted within a mounting sleeve, and an indoor grille and an outdoor grille are attached to cover exposed portions of the HVAC unit.
In some embodiments, one or both of the adjacent studs are configured with a power outlet, such as an AC voltage wall socket, or include a hole through which electrical wiring can be strung to access a power outlet. The mounting sleeve 14 can be configured with one or more side openings, such as side openings 28 shown in
The HVAC unit 12 and the mounting sleeve 14 each include complementary mounting apparatuses for mounting the HVAC unit 12 to the mounting sleeve 14. In the exemplary configuration shown in
In some embodiments, the front side access panel 10 and the HVAC unit 12 can be installed into the mounted mounting sleeve 14 by pivoting from a resting position on the floor.
Various materials can be added to provide thermal, sound, and water isolation. In particular, thermal and sound resistant materials can be included to provide thermal and sound isolation of the HVAC unit from the interior dwelling. Water resistant materials can be used to manage condensate formed in the evaporator section.
Condensate forms in the evaporator section 4 and may form on the outer surfaces of the evaporator section 4 and portions of the mounting sleeve 14 in contact with the evaporator section 4. Moisture barriers are positioned to prevent condensate from entering the mechanical section 6. A moisture barrier 54 can be positioned between the evaporator section 4 and the mechanical section 6. Additionally, or alternatively, a moisture barrier can be positioned on the inside bottom surface of the evaporator section 4. Another moisture barrier 54 can also be positioned between the mechanical section 6 and the condenser section 8. A moisture barrier trim 55 can also be positioned around a perimeter of the back side facing grille 16 without blocking the grille. The moisture barriers 54 and moisture barrier trim 55 can be made of any type of moisture resistance material, such as a spray, film, or separate panel of material applied to the surfaces of the evaporator section 4 and/or the mechanical section 6.
Additionally, or alternatively, the HVAC system 2 can be configured to collect and displace condensate.
Condensate within the evaporator section 4 drains to a bottom surface of the evaporator section 4. One or more drain holes or drain tubes can be positioned at the bottom surface of the evaporator section 4 to enable condensate to drain out of the evaporator section 4. In some embodiments, the condensate drains out of the evaporator section 4 and down the interior side surface of the mounting sleeve 14. In some embodiments, condensate output from the evaporator section 4 is directed via drain tubes to the bottom surface of the mounting sleeve 14. In other embodiments, the condensate is enabled to drain across the condenser coil in the condenser section 8 via gravity.
The physical positioning, relative alignment, and dimensions of each of the individual components in each of the evaporator section 4 and the condenser section 8 can vary according to numerous different configurations and applications. In some embodiments, the air mover is positioned to a lateral side of the heat exchanger, i.e. horizontal to the heat exchanger, in either or both of the evaporator section 4 and the condenser section 8.
In the above described configurations, the evaporator section has indoor ventilation, via the front side opening in the mounting sleeve and the front side grille, but no outdoor ventilation. In other embodiments, the evaporator section, mounting sleeve, and dwelling wall can be configured to include outdoor ventilation.
Alternatively to a lateral configuration, a stacked configuration can be used where the air mover is positioned above or below the heat exchanger, i.e. vertical to the heat exchanger, in either or both of the evaporator section 4 and the condenser section 8. An example of such a stacked configuration is described in the U.S. Patent Application Ser. No. 62/788,350, entitled “HVAC System with Coil Arrangement in Blower Unit”, which is hereby incorporated in its entirety by reference.
Similar lateral or stacked configurations can be used for the condenser section 8, except instead of the input air being input from and output to an interior of the dwelling, air is input from and output to an exterior of the dwelling via a back side grille, such as the back side grille 16. It is understood that such a condenser section can also be configured with interior ventilation to enable mixing of air, such as used in the configuration shown in
The present application has been described in terms of specific embodiments incorporating details to facilitate the understanding of the principles of construction and operation of the HVAC system. Many of the components shown and described in the various figures can be interchanged to achieve the results necessary, and this description should be read to encompass such interchange as well. As such, references herein to specific embodiments and details thereof are not intended to limit the scope of the claims appended hereto. It will be apparent to those skilled in the art that modifications can be made to the embodiments chosen for illustration without departing from the spirit and scope of the application.
This Patent Application claims priority under 35 U.S.C. 119(e) of the U.S. provisional patent application, Application Ser. No. 62/788,314, filed on Jan. 4, 2019, and entitled “HVAC Control System”, U.S. provisional patent application, Application Ser. No. 62/788,334, filed on Jan. 4, 2019, and entitled “HVAC System with Modular Architecture”, U.S. provisional patent application, Application Ser. No. 62/788,342, filed on Jan. 4, 2019, and entitled “HVAC System with Single Piece Body”, U.S. provisional patent application, Application Ser. No. 62/788,350, filed on Jan. 4, 2019, and entitled “HVAC System with Coil Arrangement in Blower Unit”, which are each hereby incorporated in their entireties by reference.
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