Patent Application
20200271330
The present embodiments relate to a method and apparatus for a package cassette room air conditioner mounted into a ceiling or attic.
A typical residential dwelling may include a central AC system, window air conditioner, or portable air conditioner. Thus, there is a need to provide a package cassette room air conditioner mounted in the ceiling and/or attic space to cool an area within the dwelling while maximizing the available space of the dwelling (e.g. maintaining floor and/or window space).
In some embodiments, the ceiling air conditioner may include a condenser unit, an evaporator unit, a soffit outlet, and/or a soffit inlet. In various embodiments, both the condenser unit and the evaporator unit may be secured to ceiling joists and positioned within an opening defined by the ceiling joists. In addition, in some embodiments, the ceiling air conditioner may include an air inlet duct adapted to be in fluid communication with the condenser unit and the soffit inlet. In various embodiments, the ceiling air conditioner may include an air discharge duct in fluid communication with the condenser unit and the soffit outlet.
In addition, in some embodiments, the ceiling air conditioner may include a drain line and a soffit drain outlet, wherein the drain line may be in fluid communication with the condenser unit and the soffit drain outlet. In various embodiments, one or more outlet housings may define the soffit inlet, the soffit outlet, and the soffit drain outlet. In some embodiments, one or more outlet housings may define the soffit inlet and the soffit outlet. In addition, in various embodiments, the evaporator unit may be secured to the ceiling joists and the condenser unit may be supported on the evaporator unit. In some embodiments, the ceiling air conditioner may include acoustic and vibration isolation structure interconnecting the evaporator unit and the condenser unit. In various embodiments, the evaporator unit may include a grill configured to be adjacent a ceiling, wherein the grill may include one or more light sources. Moreover, in some embodiments, the condenser unit may include a condensate drip tray positioned over one or more condenser coils.
In some embodiments, the ceiling air conditioner may be adapted to be installed in a ceiling. In various embodiments, the ceiling air conditioner may include a condenser unit positioned above an evaporator unit by one or more acoustic and vibration isolation structure. In addition, in some embodiments, both the condenser unit and the evaporator unit may be secured to ceiling joists and positioned within an opening defined by the ceiling joists. In various embodiments, the evaporator unit may be attached to the ceiling joists. In some embodiments, one or more outlet housings may define a soffit outlet and a soffit inlet. In various embodiments, the ceiling air conditioner may include an air inlet duct adapted to be in fluid communication with the condenser unit and the soffit inlet. In some embodiments, the ceiling air conditioner may include an air discharge duct in fluid communication with the condenser unit and the soffit outlet.
In addition, in some embodiments, the ceiling air conditioner may include a drain line and a soffit drain outlet, wherein the drain line may be in fluid communication with the condenser unit and the soffit drain outlet. In various embodiments, the one or more outlet housings may define the soffit drain outlet. In some embodiments, the evaporator unit may include a condensate pump and the condenser unit may include at least one of a condensate drip tray positioned over one or more condenser coils and a slinger tray, wherein the condensate pump may be in fluid communication with the at least one of the condensate drip tray and the slinger tray. In various embodiments, the soffit outlet and the soffit inlet may be positioned at a lower elevation within a soffit of a building structure than the condenser unit. In some embodiments, each one of the air inlet duct and the air discharge duct may extend from a sidewall of the condenser unit.
In some embodiments, the method of installing a ceiling air conditioner may comprise the step of mounting a condenser unit and an evaporator unit within an opening between ceiling joists of a building structure. In various embodiments, the method may include mounting a soffit outlet to a soffit of the building structure. In some embodiments, the method may include mounting a soffit inlet to the soffit of the building structure. In various embodiments, the method may include connecting one or more ducts in fluid communication with the condenser unit and each one of the soffit inlet and the soffit outlet within the soffit of the building structure.
In addition, in some embodiments, the method may include connecting a drain line from the condenser unit to a soffit drain outlet within the soffit of the building structure. In various embodiments, the method may include installing the condenser unit and the evaporator unit upwards between the ceiling joists of the building structure. In various embodiments, the step of connecting one or more ducts may further include extending the one or more ducts downwardly towards each one of the soffit outlet and the soffit inlet. Moreover, in some embodiments, the method may include creating one or more openings within the soffit of the building structure to receive at least one of the soffit outlet and the soffit inlet. In various embodiments, the step of mounting the condenser unit and the evaporator unit may include the step of securing the condenser unit to the ceiling joists of the building structure.
These and other advantages and features, which characterize the embodiments, are set forth in the claims annexed hereto and form a further part hereof. However, for a better understanding of the embodiments, and of the advantages and objectives attained through its use, reference should be made to the Drawings and to the accompanying descriptive matter, in which there is described example embodiments. This summary is merely provided to introduce a selection of concepts that are further described below in the detailed description, and is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in limiting the scope of the claimed subject matter.
In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention.
Numerous variations and modifications will be apparent to one of ordinary skill in the art, as will become apparent from the description below. Therefore, the invention is not limited to the specific implementations discussed herein.
The embodiments discussed hereinafter will focus on the implementation of the hereinafter-described techniques and apparatuses within a residential, commercial, and/or building structure 1 such as housing structure, such as the type that may be used in single-family or multi-family dwellings, or in other similar applications. However, it will be appreciated that the herein-described techniques and apparatuses may also be used in connection with other types of building structures in some embodiments. For example, the herein-described techniques may be used in commercial applications in some embodiments. Moreover, for example, the air conditioner 20 mounted in a ceiling 2 and/or an attic 3 may be a four-way cassette or two-way cassette in some embodiments.
As shown in the Figures, one or more air conditioners 20 may be used within one or more rooms or zones 4 within the housing or building structure 1, such as but not limited to a residential dwelling or other building structure. A roof 5 on the building structure 1 defines the attic 3 space above the ceiling structure or joists 6. The joists 6 of the ceiling 2 are spaced from each other to define an opening or space 7 therebetween. The opening 7 between two parallel joists may be within the ceiling 2 and/or attic 3 allowing the air conditioner 20 to be secured to the joists 6 or other structure of the ceiling/attic structure. The air conditioner 20 (e.g. the evaporator unit and/or condenser unit) is mounted or secured to the joists 6. The opening 7 between the joists 6 and/or ceiling 2 may be made during new and/or after the new construction (e.g. old construction). For example, the air conditioner 20 or portions thereof may be installed before and/or after the ceiling or portions thereof 2 is installed. The air conditioner or unit 20 may be inserted into the one or more openings 7 of the ceiling 2 and/or joists 6 without having to add additional ceiling joists and/or alter existing ceiling joists. The opening 7 within the ceiling 2 (e.g. ceiling panel/drywall of the attic or space) may need to be cut, formed, or created before installation of the air conditioner 20 before and/or after mounting in various embodiments. Although a dual duct (e.g. 50, 60) is shown, it should be understood that a single duct could be use. Moreover, although not shown, dampers may allow for ventilation and fresh air exchange of the conditioned space in addition to the standard cooling function. Cross-flow blowers, not shown, may also be used in some embodiments to reduce noise. Compressor and inverter technology may be used as well as cool only and heat pump configuration. In some embodiments, Wi-Fi control, voice control, infrared occupancy detection, facial recognition with preferences, and/or different BTU sizes may be used. Condensate may be controlled by slinging and/or drain lines (e.g. 70).
As shown in
The air conditioner 20 may be in fluid communication with the one or more rooms and zones 4 and the exterior of the building structure 1. The air conditioner 20 (e.g. condenser unit and/or evaporator unit) may be in communication with the building structure exterior via one or more soffits 8.
One or more soffits or horizontal structure 8 of the building structure 1 may be covered by the roof 5 or portions thereof. In the one embodiment shown, one or more outlet housings 22 may be used or mounted within the soffit 8 and be in fluid communication with the air conditioner 20 mounted in the ceiling 2. The soffit 8 may include a variety of panels, exterior panels, or other exterior structure. The soffit 8 may be positioned underneath a portion of the roof line 5. The one or more outlet housings 22 may include, but is not limited to a soffit inlet 62, a soffit outlet 52, and/or a soffit drain outlet 72. Although the inlets and/or outlets of the soffit 8 are shown as individual pieces or structures, it should be understood that the one or more of the inlets or outlets may be combined into a single piece, structure, or arrangement within the soffit 8 and still be within the scope of the invention. The soffit outlet and/or inlet may be a continuous screened vent, one or more openings, or a louvered vent. The soffit inlet, soffit outlet, and/or drain outlet may be sealed by a variety of methods or constructions.
Although not shown, a variety of split versions may be used with a condenser placed outdoors. The split version may have one or more indoor ceiling mounted evaporator units sharing the outdoor condenser.
In some implementations, the air conditioner may include one or more air inlet ducts 60 extending from the air conditioner 20 to the soffit 8. As shown in
In some implementations, the air conditioner may include one or more air discharge ducts 50 extending from the air conditioner 20 to the soffit 8. As shown in
In some embodiments, the air conditioner may include one or more drain lines 70, if used, extending from the air conditioner 20 to the soffit 8. As shown in
In various implementations, the drain line 70, the discharge duct 50, and/or the air inlet duct 60 may extend from one or more portions of the air conditioner 20. As shown in
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In some implementations, as shown in
In use, the ceiling air conditioner may be installed in a variety of ceiling and/or attic structures 2. The air conditioner 20 may be installed separately by portions thereof or as a single unit. For example, the evaporator unit 40 may be installed with the condenser unit 30 or separately therefrom.
The user (e.g. consumer or installer) may create a hole or opening in the ceiling of old/new construction. A hole may be created in the ceiling structure or panel, however, the ceiling structure(s) or drywall may be installed after the air conditioner or portions thereof is installed. The user can lift and insert the air conditioner upwardly through the opening 7 between the ceiling joists 6. Although the unit, or portions thereof, may be inserted downwardly from above the joists or from the attic space in some embodiments. Upon placement of the one or more portions/units of the air conditioner within the opening or aperture, the user may mount the condenser unit 30 and/or evaporator unit 40 to the one or more ceiling joists 6. The user may use a variety of attachment mechanism to secure the air conditioner, or portions thereof, to the ceiling joists (e.g. brackets, fasteners, or cables). In addition, fasteners or devices may be coupled to the rafters, other than horizontal joists, in some embodiments. The soffit outlet, soffit inlet, and/or soffit drain outlet may be mounted within the soffit structure of the building. One or more apertures or openings may be created in the soffit structure to receive or mount the one or more outlet housings. The aperture within the soffit or portions thereof may be created after mounting the one or more outlet housings in some embodiments. The ducts and/or drain lines (e.g. air discharge duct, air inlet duct, and/or drain line) may be connected to the one or more housings mounted in the soffit and the air conditioner (e.g. condenser unit). The one or more ducts and/or drain lines may be extended downwardly towards the one or more outlet housings within the soffit. It should be understood a variety of fasteners and/or seals may be used at the opposing ends of the ducts and/or lines adjacent the soffit and/or air conditioner to attach the respective ends.
While several embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, embodiments may be practiced otherwise than as specifically described and claimed. Embodiments of the present disclosure are directed to each individual feature, system, article, material, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, and/or methods, if such features, systems, articles, materials, and/or methods are not mutually inconsistent, is included within the scope of the present disclosure.
All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.
The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.”
The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and/or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.
As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of” “Consisting essentially of,” when used in the claims, shall have its ordinary meaning as used in the field of patent law.
As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and/or B”) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.
It should also be understood that, unless clearly indicated to the contrary, in any methods claimed herein that include more than one step or act, the order of the steps or acts of the method is not necessarily limited to the order in which the steps or acts of the method are recited.
In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of” shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures, Section 2111.03.
It is to be understood that the embodiments are not limited in its application to the details of construction and the arrangement of components set forth in the description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Unless limited otherwise, the terms “connected,” “coupled,” “in communication with,” and “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings.
The foregoing description of several embodiments of the invention has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the invention to the precise steps and/or forms disclosed, and obviously many modifications and variations are possible in light of the above teaching.
