MODULAR HVAC UNIT CABINET

Abstract

The present disclosure relates to a modular heating, ventilation and air conditioning (HVAC) system comprising a compressor module, evaporator module, and optionally a condenser module which can be operatively connected in a variety of configurations. The compressor module, evaporator module, and condenser module comprise a plurality of detachably connected panels.

Description

FIELD OF DISCLOSURE

The present disclosure relates to modular heating, ventilation, and air conditioning (HVAC) systems, the components of which can be arranged in a variety of configurations.

BACKGROUND

HVAC systems are integral to modern infrastructure-providing essential heating, cooling, and ventilation to enclosed spaces and ensuring that individuals inside modern structures remain comfortable. However, conventional HVAC systems are generally large, bulky, and difficult to configure to smaller or non-conventional spaces. This is because conventional HVAC systems are complex and require a large number of individual components to function, including a compressor system, an evaporator system, a condenser system, and the appropriate valves, regulators, filters, and electrical monitors to ensure that the HVAC system operates properly and are installed in enclosures that have a fixed configuration. The result is a bulky HVAC system that cannot be reconfigured and is difficult to fit into smaller spaces or into spaces with existing physical obstructions.

Therefore, there is a long felt need for an HVAC system that can be configured to operate in a variety of spaces, including spaces where there is limited room for traditional HVAC equipment.

SUMMARY

The present disclosure relates to a modular HVAC system with customizable components which can be arranged in multiple configurations as may be required to fit into a particular space.

The modular HVAC system may comprise a modular, discrete, and customizable compressor unit, a modular, discrete, and customizable evaporator unit, and, optionally, a modular, discrete, and customizable air-cooled condenser unit. These modular component units may be arranged and connected in many configurations or in any order, so that one unit may be connected to any other unit by means of flexible connecting tubes which may be lengthened or shortened as necessary to operatively connect to the various HVAC components. These modular units (i.e., the compressor unit, the evaporator unit, and the condenser unit) include the same functional components that are normally all contained in one rigid fixed system configuration of a conventional HVAC system, but as disclosed here the modular units may be independently positioned as required and can each be operatively connected. The modularity of and between these units allows the units to be configured in a variety of arrangements to suit the needs of a particular user or the restrictions of a particular space.

In an embodiment, the present disclosure is a modular HVAC system comprising an evaporator unit including a perimeter support structure defining a cubic frame having six openings and a compressor unit including a perimeter support structure defining a cubic frame having six openings. A first set of a plurality of panels are selectively and removably connected to the cubic frame of the compressor unit to cover five out of the six openings and define a first uncovered opening. One of the first set of the plurality of panels includes an air discharge port. A second set of a plurality of panels are selectively and removably connected to the cubic frame of the evaporator unit to cover five out of the six openings and define a second uncovered opening. One of the second set of the plurality of panels includes an air intake port. The compressor unit and evaporator unit are detachably connected to align the first uncovered opening of the compressor unit and the second uncovered opening of the evaporator unit to define a system configuration.

In an embodiment, the system configuration is selectively one of thirty-six different configurations based on selection of the first uncovered opening and second uncovered opening.

In an embodiment, the modular HVAC system further comprises a condenser unit operatively connected to the evaporator unit. The condenser unit includes a perimeter support structure defining a frame of the condenser unit and having a plurality of openings. A third set of a plurality of panels are selectively and removably connected to the frame of the condenser unit to cover the plurality of openings.

In an embodiment, the condenser unit comprises six openings and the third set of the plurality of panels covers the six openings. One of the third set of the plurality of panels is a first refrigerant panel comprising a refrigerant inlet and outlet. One of the second set of the plurality of panels of the evaporator unit is a second refrigerant panel comprising a refrigerant inlet and outlet. The condenser unit and evaporator unit are detachably connected to align the first refrigerant panel of the condenser unit with the second refrigerant panel of the evaporator to define a condenser system configuration.

In an embodiment, the condenser unit comprises three openings. The third set of the plurality of panels covers the three openings. One panel of the second set of the plurality of panels of the evaporator unit is a second refrigerant panel comprising a refrigerant inlet and outlet. The condenser unit comprises a refrigerant inlet and outlet which detachably connect to the second refrigerant panel.

In an embodiment, the modular HVAC system comprises a mixing box unit. The mixing box unit comprises a perimeter support structure defining a cubic frame having six openings. A fourth set of a plurality of panels are selectively and removably connected to the cubic frame of the mixing box unit to cover five of the six openings and define a third uncovered opening. Two of the panels comprise dampening panels. A first dampening panel intakes ambient outdoor air and a second dampening panel intakes ambient indoor air. The mixing box unit and evaporator unit are detachably connected to align a third uncovered opening of the mixing box and the panel of the evaporator unit having the air intake port to define a mixing box system configuration.

In an embodiment, the compressor unit and the evaporator unit define an airflow pathway entering the air intake port disposed on the evaporator unit, moving through the first and second opening of the evaporator unit and compressor unit, and exiting the air discharge port disposed on the compressor unit.

In an embodiment, the panel of the evaporator unit having an air intake port is a filter panel, and the filter panel comprises a filter housing extending from the filter panel. In an embodiment, the filter panel is oriented adjacent to a condenser coil apparatus disposed within a the cubic frame of the evaporator unit.

In an embodiment, the first set of the plurality of panels comprises an electrical panel having an electrical box, the electrical panel controlling power to the HVAC system and to internal components of the compressor unit and evaporator unit.

In an embodiment, the compressor unit comprises a plurality of internal components. The plurality of internal components include, but are not limited to, a compressor rack and a suction accumulator. The plurality of internal components are detachably connected to a bottom frame rail of the compressor unit and extend upward from the bottom frame rail. The bottom frame rail is the rail of the cubic frame oriented along the lowest horizontal plane of the compressor unit.

In an embodiment, the evaporator unit comprises a plurality of internal components. The plurality of internal components include, but are not limited to a condenser coil and a receiver. The plurality of internal components are detachably connected to a bottom frame rail of the evaporator unit and extend upward from the bottom frame rail. The bottom frame rail is the rail of the cubic frame oriented along the lowest horizontal plane of the evaporator unit.

Accordingly, it is an object of the disclosure not to encompass within the disclosure any previously known product, process of making the product, method of using the product, or method of treatment such that Applicants reserve the right and hereby disclose a disclaimer of any previously known product, process, or method. It is further noted that the disclosure does not intend to encompass within the scope of the disclosure any product, process, or making of the product or method of using the product, which does not meet the written description and enablement requirements of the USPTO (35 U.S.C. § 112, first paragraph) or the EPO (Article 83 of the EPC), such that Applicants reserve the right and hereby disclose a disclaimer of any previously described product, process of making the product, or method of using the product disclosed herein.

It is noted that in the present disclosure and particularly in the claims and/or paragraphs, terms such as “comprises,” “comprised,” “comprising,” and the like can have the meaning attributed to them in U.S. patent law; e.g., they can mean “includes,” “included,” “including,” and the like, and that terms such as “consisting essentially of” and “consists essentially of” have the meaning ascribed to them in U.S. patent law, e.g., they allow for elements not explicitly recited, but exclude elements that are found in the prior art or that affect a basic or novel characteristic of the invention.

These and other embodiments are disclosed or are obvious from and encompassed by the following Brief Description of the Drawings and Detailed Description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of a compressor unit, an evaporator unit, and a condenser unit disposed in one embodiment of the present disclosure.

FIG. 2 is an illustration of a compressor unit and an evaporator unit disposed in one embodiment of the present disclosure.

FIG. 3A is an illustration of an evaporator unit in one embodiment of the present disclosure where the side panels or walls have been removed to illustrate one embodiment of the arrangement of its internal components.

FIG. 3B is an illustration of an evaporator assembly for installation in the evaporator unit.

FIG. 4A is an illustration of a compressor unit in one embodiment of the present disclosure where the side panels or walls have been removed to illustrate one embodiment of the arrangement of its internal components.

FIG. 4B is an illustration of a compressor rack for installation in the compressor unit.

FIG. 5 is a schematic representation of the operational internal components of the compressor unit.

FIG. 6 is a schematic representation of the operational internal components of the evaporator unit.

FIG. 7a is a schematic representation of the operational internal components of the condenser unit.

FIG. 7b is an illustration of the condenser unit in one embodiment of the present disclosure where the side panels or walls have been removed to illustrate one embodiment of the arrangement of its internal components.

FIG. 8 is an illustration of the connectors and flexible tube used to connect the evaporator unit, the condenser unit, and the compressor unit.

FIG. 9 is a schematic representation of the connectivity between each of the compressor unit, evaporator unit, and the condenser unit.

FIGS. 10-21 each depict a potential configurations of the compressor, evaporator and panel systems.

FIG. 22 is a front view of a remote panel used in connection with an evaporator unit or a compressor unit to connect to a condenser unit.

FIG. 23 is a perspective view of a mixing box used in connection with one embodiment of the present disclosure.

FIG. 24 is a perspective view of an embodiment of a compressor unit with side panels comprising multiple sheets of material. One panel is removed from the device to show internal components of the compressor unit.

FIG. 25 is a rear view of an embodiment of an evaporator unit without a condenser coil therein and having a remote panel attached thereto. One panel is removed from the device to show the interior of this embodiment of the evaporator unit.

FIG. 26 depicts a perspective view of the embodiment of the evaporator unit in FIG. 25 having a filter panel attached at one side of the evaporator.

FIG. 27 depicts a second perspective view of the embodiment of the evaporator unit in FIG. 25.

FIG. 28 depicts a perspective view of an embodiment of a condenser unit with a rear wall removed to depict the interior of the condenser unit.

FIG. 29 depicts a side view of the embodiment of the condenser unit of FIG. 28.

FIG. 30 depicts a perspective view of a second embodiment of a condenser unit having a triangular frame and a fan disposed on a panel of the condenser unit.

FIG. 31 depicts a side-perspective view of the second embodiment of the condenser unit of FIG. 30.

FIG. 32 depicts a side view of the second embodiment of the condenser unit of FIG. 30. One panel is removed from the device to show the interior of this embodiment of the condenser unit.

DETAILED DESCRIPTION

The following detailed description, given by way of example, but not intended to limit the invention solely to the specific embodiments described, may best be understood in conjunction with the accompanying drawings.

FIG. 1 depicts an embodiment of a modular HVAC system 100 in accordance with the present disclosure and its discrete, modular components, including a compressor unit 110, an evaporator unit 120, and an optional condenser unit 130. Each of the compressor unit 110, evaporator unit 120, and condenser unit 130 may be approximately the same shape and size, allowing the units 110, 120, 130 to be easily arranged and connected in a variety of configurations. One of skill in the art will recognize that the shape and size of the components are not required to be approximately the same provided that certain other requirements are in compliance with the strategy of the present disclosure.

In an embodiment depicted in FIG. 1, each side of each unit 110, 120, 130 may be approximately the same size. The approximately uniformly sized units and sides allow for a highly customizable system. FIGS. 10-21 depict some of the possible configurations of the compressor unit 110, the evaporator unit 120, and the optional condenser unit 130.

Because both the placement of any unit and the arrangement of the components within the units is customizable, the modular HVAC system 100 can be arranged to a near-infinite number of configurations to meet the needs of a particular user or the restrictions of a given space, such as depicted by FIGS. 10-21 for example only and not limiting as to all possible configurations.

Compressor Unit

FIG. 2 depicts another embodiment of the modular HVAC system 100. The compressor unit 110 is an essential component of an HVAC system and compresses refrigerant to create high pressure, warm gas capable of warming the ambient air. The compressor unit 110 may comprise a perimeter support structure that may be configured from suitable components. As an exemplary embodiment, the perimeter support structure may comprise 90 degree angled metal, plastic, or other suitable materials, wherein each flange of the 90 degree angled material further comprises a plurality of apertures to facilitate connection of the 90 degree angled materials to one another and connection of internal components to the perimeter support structure. In an embodiment, the flanges of the 90 degree angled material cooperatively define a preferably cubic configuration wherein each side of the cubic configuration may include a plurality of the flanges, four on each side of the cubic configuration. A side opening of the cubic configuration is cooperatively defined by the distal edges of the flanges disposed on any side. The compressor unit 110 may comprise a plurality of solid side panels 114 and a discharge side panel 104 comprising a discharge port 116. In the preferred embodiment, the compressor unit 110 comprises four solid side panels 114 and a single discharge side panel 104 comprising a discharge port 116. The discharge port 116 facilitates an air pathway between the modular HVAC system 100 and an external duct system or external space.

As depicted in FIG. 2, one side of the compressor unit 110 is operatively connected to the evaporator unit 120. The side of the compressor unit 110 and evaporator unit 120 that are connected preferably do not have any side panel installed. However, side panels could be connected to any opening of the perimeter support structure of each of the units provided that aligned openings of the compressor unit 110 and evaporator unit 120 are provided to facilitate an air pathway between the units 110, 120.

The other five sides of the compressor unit 110 (i.e., the sides that are not operatively connected to the evaporator unit 120) may comprise four solid side panels 114 and a discharge side panel 104. Any solid side panel 114 may be replaced with an alternative panel type or modified to include additional components to operatively connect to another portion of the HVAC system 100, such as the condenser unit 130. The solid side panels 114 are interchangeable with one another, such that any one solid side panel 114 may be in the position of any other solid side panel 114 as may be required for a particular configuration of the HVAC system 100.

For example, any one of the solid side panels 114 may comprise an electric panel 102, which covers the opening defined by the perimeter structure within which the electrical box 144 is disposed so as to cover not only the opening, but also to cover and enclose the electrical box 144. Further, in alternative embodiments, the solid side panels 114 may be modified to comprise a discharge port 116, which must be disposed in communication with the blower 150 to facilitate an airflow pathway from the interior of the compressor unit 110 to exterior of the compressor unit 110, such as an enclosed space, ductwork, or other suitable discharge location or direction.

The solid side panels 114 and discharge panel 104 may be applied to the perimeter support structure in any configuration as may be required. For example, the discharge panel 104 may be applied to the top, bottom, or any side of the perimeter support structure and the solid side panels 114 may be applied to any of the remaining opening of the perimeter support structure.

Further, the position of the components within each of the solid side panels 114 and discharge panel 104 may be arranged as needed. The position of the discharge port 116 may be fixed in multiple locations along the discharge panel 104 of the compressor unit 110. Specifically, the discharge port 116 may be positioned in any one of the four quadrants of the discharge panel 104, along the side or top of the discharge panel 104, or in the corner of the discharge panel 104, as may be necessary or desired for a particular configuration. In an alternative embodiment, the discharge port 116 may be positioned in the center of the discharge panel 104.

The compressor unit 110 may be operatively connected to the evaporator unit 120 by means of a plurality of connectors 154a, 154b (see FIGS. 4 and 5). In an embodiment, the compressor unit is operatively connected to a condenser unit 130 by means of the plurality of connectors 154a, 154b. In another embodiment, the compressor unit 110 may be operatively connected to both the evaporator unit 120 and condenser unit 130 by means of the plurality of connectors 154a, 154b. The connectors 154a, 154b may be comprised of (or may be used in connection with) a flexible tubing 156 and the components within the compressor unit 110 can be arranged as needed while still being operatively connected to the evaporator unit 120 and/or condenser unit 130.

In an embodiment, the plurality of side panels 114 are comprised of two abutting sheets 114a, 114b. In such embodiments the side panels comprise a first sheet and second sheet 114a, 114b. The first and second sheet 114a, 114b may be oriented in any arrangement to cover an opening defined by the perimeter structure of the compressor unit 110. The dual sheets of material 114a, 114b improves modularity of the compressor unit 110. For example, the sheet 114a, 114b having the discharge port 116 can be oriented to position the discharge port 116 in any desired position along a side of the compressor unit 110. As such, the discharge port 116 may be positioned as desired in any of the four corners of any of the six sides of the compressor unit 110.

In addition, a user can easily remove one of the sheets 114a, 114b to access the internal components of the compressor unit 110 without uncovering the entire side of the compressor unit 110. For example, a user can access electrical box 144 without disturbing the flow of supply air out the discharge port 116 (and vice versa).

Evaporator Unit

FIG. 2 also depicts one embodiment of the evaporator unit 120 that facilitates heat transfer within the HVAC system 100. The evaporator unit 120 may comprise a perimeter support structure that may be configured from suitable components. As an exemplary embodiment, the perimeter support structure may comprise 90 degree angled metal, plastic, or other suitable materials, wherein each flange of the 90 degree angled material further comprises a plurality of apertures to facilitate connection of the 90 degree angled materials to one another and connection of internal components to the perimeter support structure. In an embodiment, the flanges of the 90 degree angled material cooperatively define a preferably cubic configuration wherein each side of the cubic configuration may include a plurality of the flanges, four on each side of the cubic configuration. A side opening of the cubic configuration is cooperatively defined by the distal edges of the flanges disposed on any side.

The evaporator unit 120 may comprise a plurality of solid side panels 114 and one side opening for air intake. In the preferred embodiment, the evaporator unit 120 comprises four solid side panels 114 and a side opening for air intake comprising a filter housing 106 and air intake port 108. The filter housing 106 facilitates intake of ambient air to be treated by the HVAC system 100. In an embodiment, a filter panel 112 may be disposed within the opening of the air intake port.

As depicted in FIG. 2, one side of the evaporator unit 120 is operatively connected to the compressor unit 110. The side of the compressor unit 110 and evaporator unit 120 that are connected preferably do not have any side panels installed. However, side panels could be connected to any opening of the perimeter support structure of each of the units provided that aligned openings of the compressor unit 110 and the evaporator unit 120 are provided to facilitate an air pathway between the units 110, 120. To function appropriately, each of the evaporator unit 120 and compressor unit 110 must comprise a filter housing 106 and discharge panel 104 respectively. Therefore, the units 110, 120 cannot be connected between the filter housing 106 and discharge panel 104.

The other five sides of the evaporator unit 120 (i.e., the sides that are not operatively connected to the compressor unit 110) may comprise four solid side panels 114 and a filter housing 106. The solid side panels 114 are interchangeable with one another, such that any one solid side panel 114 may be in the position of any other solid side panel 114 as may be required for a particular configuration of the HVAC system 100.

In an alternative embodiment, any solid side panel 114 may be replaced with an alternative panel type (such as a filter housing 106).

The solid side panels 114 may be applied to the perimeter support structure in any configuration as may be required. In an embodiment, the filter housing 106 may be applied to the top, bottom, or any side of the perimeter support structure and solid side panels 114 may be applied to the remaining openings of the perimeter support structure (except for the side of the evaporator unit 120 which is attached to a side of the compressor unit 110). In another embodiment, the filter housing 106 is placed adjacent to the coil assembly 132, specifically the condenser coil.

In an embodiment, the filter housing 106 comprises an air intake port 108 and a filter panel 112 disposed within the air intake opening. In this embodiment, the filter housing 106 and air intake port 108 may comprise any size (within the same dimensions of any solid side panel 114) or planar shape.

In an alternative embodiment, the filter housing 106 is an optional assembly which includes a shroud connected to and extending from the perimeter support structure. A filter panel 112 is removably disposed within the filter housing 106 to filter the ambient air entering through the air intake port 108.

The evaporator unit 120 is operatively connected to the compressor unit 110 by a plurality of connectors 154a, 154b (and optionally 154c). In an embodiment, the compressor unit is operatively connected to a condenser unit 130 by means of the plurality of connectors 154a, 154b, 154c. In another embodiment, the evaporator unit 120 is operatively connected to both the condenser unit 130 and compressor unit 110 by means of a plurality of connectors 154a, 154b, 154c. The connectors 154a, 154b, 154c may be comprised of (or used in connection with) a flexible tubing and the components within the evaporator unit 120 can be arranged as needed while being operatively connected to the compressor unit 110 and/or the condenser unit 130.

In embodiments of the evaporator unit 120 comprising the coil assembly 132 (i.e., a condenser coil), the evaporator unit 120 does not need to be connected to a condenser unit 130. In embodiments of the evaporator unit 120 which do not include the condenser coil 132 (as depicted in FIG. 25), the evaporator unit 120 must be connected to a condenser unit 130.

An evaporator unit 120 comprising a coil assembly 132 (i.e., a condenser coil) is preferred where there is easily accessible water supply infrastructure to be used for building cooling. If no water supply is available, an evaporator unit 120 without the coil assembly 132 may be selected (depicted in FIGS. 25-26), but may require installation of additional air ducts, refrigerant tubing, roof space and/or louvers to move air in and out of the building.

In an embodiment, one side of the evaporator unit 120 is operatively connected to the condenser unit 130. The side of the condenser unit 130 and evaporator unit 120 that are connected preferably do not have any side panels installed. However, side panels could be connected to any opening of the perimeter support structure of each of the units 120, 130 provided that aligned openings of the condenser unit 130 and the evaporator unit 120 are provided to facilitate an air pathway between the units 130, 120.

In embodiments where the sides of the condenser unit 130 and evaporator unit 120 are not directly connected, the evaporator unit 120 includes at least one remote panel 200. The remote panel comprises refrigerant inlets and outlets 202, 204 to operatively connect the evaporator unit 120 and condenser unit 130. Other than the refrigerant inlets and outlets 202, 204, the remote panel 200 is generally the same as the solid side panels 114 used on other sides of the evaporator unit 120. As with any of the other panels 114, the remote panel 200 can be placed on any side of the evaporator unit 120.

Condenser

FIGS. 1, 7 a, and 7b comprise an air condenser unit 130 which may be operatively connected to the HVAC system 100. The condenser unit 130 is optionally used with the evaporator unit 120 and compressor unit 110 to provide additional cooling or warming to the refrigerant within the system 100. The air condenser unit 130 may comprise a perimeter support structure that may be configured from suitable components. In the preferred embodiment, the condenser unit 130 comprises a condenser coil 170 and fan 172. In the embodiment depicted in FIG. 7b, the condenser coil 170 is located proximate a first side of the perimeter support structure and the fan 172 is located on a second side of the perimeter support structure opposite the condenser coil 170. In the preferred embodiment, the condenser coil further comprises a plurality of condenser tubes which expand into coil headers 174. In the preferred embodiment, the condenser coil 170 may not be placed on the top or bottom sides of the air condenser unit 130.

In the preferred embodiment, the fan 172 is detachably connected to a fan bulkhead panel 176. The fan bulkhead panel 176 is similar in size and dimensions to the solid side panels 114, however, the fan bulkhead panel 176 further comprises an air inlet to feed ambient air to the fan 172. After the condenser coil 170 cools or warms the refrigerant, the ambient air escapes through the same side as the condenser coil 170. In the preferred embodiment, the side with the condenser coil does not include a solid side panel 114. In the preferred embodiment, solid side panels 114 are placed along the four remaining sides of the condenser unit 130.

In an embodiment, the air exiting the condenser unit 130 may be discharged to an environment other than the enclosed space.

In an embodiment, the condenser unit 130 may work in tandem with the evaporator unit 120 and compressor unit 110 as part of the modular HVAC system 100 to provide heat, ventilation, and air conditioning to an enclosed space. The condenser unit 130 is a similarly constructed cube-like unit comprising a plurality of solid side panels 114 and can be operatively connected to the evaporator unit 120 and compressor unit 110 as may be desired. The condenser unit 130 can be operatively connected by means of connectors 154a, 154b and flexible tubing 156, which allow the condenser unit 130 to be positioned in a variety of configurations, including disposed remotely from the compressor unit 110 or evaporator unit 120. In an embodiment, the flexible tubing 156 may be replaced with field condenser connections.

In the embodiment depicted in FIG. 7a refrigerant enters the condenser unit 130 through one of the connectors 154a, 154b, the refrigerant is warmed or cooled as it passes the condenser coil 170, and the refrigerant exits the condenser unit 130 through one of the connectors 156a, b.

FIGS. 27-29 depict an indoor embodiment of the condenser unit 130. The outdoor embodiment of the condenser unit 130 may include a panel 114 with connectors 154a, 154b along one side of the condenser unit 130 where the condensing unit 130 is remotely connected to the evaporator unit 120. In embodiments where the condenser unit 130 is directly connected to the evaporator unit 120, an open side of the condenser unit 130 connects to an open side of the evaporator unit 120. In an embodiment, the condenser unit 130 may optionally comprise a filter panel 112 with the same components as the filter panel 112 used in connection with the evaporator unit 120.

FIGS. 30-32 depict an outdoor embodiment of the condenser unit 430. The outdoor condenser unit 430 comprises generally the same elements as the indoor condenser unit 130 unless otherwise disclosed herein. As depicted in FIGS. 30-32, the outdoor condenser unit 430 comprises a perimeter support structure to define a triangular configuration with three openings.

In the preferred embodiment, the condenser unit 430 comprises a condenser coil 170 and fan 172. The condenser coil 170 is disposed within the perimeter support structure and the fan 172 is located on a second side of the perimeter support structure. In the preferred embodiment, the fan 172 is placed on the top side of the air condenser unit 430.

In the preferred embodiment, the fan 172 is detachably connected to a fan bulkhead panel 476. The fan bulkhead panel 176 is similar in size and dimensions to the solid side panels 414, however, the fan 172 is connected on top of the bulkhead panel 176 to push air into the cavity of the condenser 430. In the preferred embodiment, solid side panels 114 are placed along the two remaining sides of the condenser unit 130.

The condenser unit 430 is operatively connected to the evaporator unit 120 by means of connectors 154a, 154b to be positioned in a position remotely from the compressor unit 110 or evaporator unit 120. A control box 402 is operatively connected to the fan to control airflow into the condenser unit 430.

In the embodiment depicted in FIGS. 30-32, refrigerant enters the condenser unit 430 through one of the connectors 154a, 154b, the refrigerant is warmed or cooled as it passes the condenser coil 470, and the refrigerant exits the condenser unit 430 through one of the connectors 156a, b.

Mixing Box Unit

FIG. 23 depicts a mixing box unit 300. The mixing box 300 comprises a perimeter support structure that may be configured from suitable components. As an exemplary embodiment, the perimeter support structure may comprise 90 degree angled metal, plastic, or other suitable materials, wherein each flange of the 90 degree angled material further comprises a plurality of apertures to facilitate connection of the 90 degree angled materials to one another and connection of internal components to the perimeter support structure. In an embodiment, the flanges of the 90 degree angled material cooperatively define a preferably cubic configuration wherein each side of the cubic configuration may include a plurality of the flanges, four on each side of the cubic configuration. A side opening of the cubic configuration is cooperatively defined by the distal edges of the flanges disposed on any side.

In an embodiment, the mixing box unit 300 may comprise a plurality of solid side panels 114, a side opening 306 to connect to the filter panel 112 of the evaporator unit 120, and a first and second dampening panel 302, 304. The first dampening panel 302 intakes outside air and the second dampening panel 304 intakes indoor air. The indoor and outdoor air are mixed/combined in the mixing box unit 300 and pass through to the evaporator unit 120 via the side opening 306.

Each dampening panel 302, 304 comprises an actuator 308, 310 to modulate the intake of indoor and outdoor air into the mixing box unit 300. The actuators 308, 310 allow the mixing box unit 300 to adjust the amount of indoor air and outdoor air to a desired mixture which then flows from the mixing box unit 300 and into the evaporator unit 120. A sensor 312 may be disposed on each respective dampening panel 302, 304 to identify the flow rate of air through the dampening panel 302, 304.

In a preferred embodiment, the filter panel 112 of the evaporator unit 120 connects to the side opening 306 of the mixing box unit 300 such that the filter housing 106 is disposed within the side opening 306 of the mixing box unit 300. In an alternative embodiment, the filter panel 112 may be removed from the evaporator unit 120 and the resulting open side of the evaporator unit 120 connects to the side opening 306 of the mixing box unit 300 to form a connection therebetween.

In embodiments where a mixture of outdoor and indoor air is not desired by the HVAC system 100, the mixing box unit 300 is not required. If desired, a mixing box unit 300 may be connected to a side opening of the compressor unit 110.

Internal Components of the Modular HVAC System

FIGS. 4A and 4B depict the internal components of the compressor unit 110. The internal components of the compressor unit 110 comprise an electrical box 144, a fan assembly 150, and a compressor rack 146. The compressor rack 146 comprises a compressor 147, a suction accumulator 152, a reversing valve 148, and the connectors 154a, 154b.

In the preferred embodiment, the compressor rack 146 is connected to the unit perimeter support structure such that the compressor 147 and accumulator 152 are disposed in a vertical orientation. Further, the fan assembly 150 is located proximate the discharge port 116 and is disposed to facilitate an air pathway between the fan assembly 150 and the external duct connected to the discharge port 116.

The electrical box 144 contains necessary components to power the HVAC system 100 and other controls, the reversing valve 148 permits the flow of refrigerant between the compressor unit 110 and the evaporator unit 120 and optionally, the condenser unit 130. The suction accumulator 152 accumulates and stores any refrigerant not in use by the compressor 147. In the preferred embodiment, the accumulator 152 and the receiver 136 are comprised of the same component. However, different orientations of this component lead to different functions. When this component is oriented in a vertical configuration, it performs a function as an accumulator 152. When this component is oriented in a horizontal configuration, it performs a function as a receiver 136. When oriented to function as an accumulator 152 this component prevents liquid refrigerant from flooding into the compressor 147.

In an embodiment, the electrical box 144 and fan assembly 150 may be connected to the perimeter support structure in any orientation so long as the fan assembly may facilitate an air pathway between the fan assembly 150 and the external duct connected to the discharge port 116. In a preferred embodiment, the electrical box 144 and fan assembly 150 are positioned on adjacent sides of the compressor unit 110 and the electrical box 144 must be placed in an upright position.

FIGS. 4A, 4B, and 5 depict an arrangement of the internal components of the compressor unit 110, however, these components may generally be arranged or configured as may be required to meet the needs of a particular arrangement or configuration of the HVAC system 100. Specifically, the compressor unit 110 must comprise one side opening having an orientation to directly connect with a corresponding side opening in the evaporator unit 120. Further, the compressor rack 146 must be connected to the compressor unit's 110 perimeter support structure such that the compressor and accumulator 152 are disposed in a vertical orientation. In addition, the fan assembly 150 and discharge port 116 must be disposed to facilitate an air pathway between the fan assembly and the external duct connected to the discharge port 116. FIG. 4B depicts the compressor rack 146 which comprises a compressor, accumulator 152, reversing valve 148, refrigerant connectors 154a, 154b, and associated piping which are all disposed along a single metal frame (e.g., a “rack”). In an alternative embodiment, each of the identified components are not disposed along a single metal frame.

FIGS. 3a and 3b depict the internal components of the evaporator unit 120. The internal components of the evaporator unit comprise a coil assembly and an evaporator assembly. The evaporator assembly comprises a liquid line solenoid valve 122, and an expansion valve 126 (electronic or otherwise), a check valve 128, a filter drier 134, a receiver 136, and a reheat valve 138. The coil assembly comprises an evaporator coil 124, a condenser coil 132, and a reheat coil 125.

To warm or cool air, the HVAC system 100 intakes ambient air via the filter housing 106. Next, the ambient air is passed over the evaporator coil 124. The evaporator coil 124 extracts heat from the air by absorbing heat through a refrigerant. Low pressure, chilled refrigerant is pulled through the evaporator coil 124 by the compressor (located within the compressor rack 146). The flow of refrigerant into the evaporator coil 124 is regulated by the expansion valve 126, which ensures that proper pressure and temperature in the evaporator unit 120 is maintained. To maintain the proper air temperature leaving the blower 150, a reheat coil 125 and reheat valve 138 ensure that the refrigerant in the HVAC system 100 heats the air leaving the evaporator unit 120 to the proper temperature. The liquid line solenoid valve 122 controls the flow direction of refrigerant through the reheat coil 125 when the HVAC system 100 switches between heating and cooling.

FIGS. 3a, 3b, and 5 depict an arrangement of the internal components of the evaporator unit 120, however, these components may be arranged as required to meet the needs of a particular arrangement or configuration of the HVAC system 100. Specifically, the evaporator unit 120 must comprise one side opening having an orientation to directly connect with a corresponding side opening in the compressor unit 110. Further, the evaporator coil 124 must be connected to the unit perimeter support structure such that the receiver 136 is disposed in a horizontal orientation. In addition, the intake port 108 must be disposed to facilitate an air pathway between the ambient air source and the side opening of the evaporator unit 120 connected to the corresponding side opening of the compressor unit 110. The compressor unit 110 may be place above, below, or alongside the evaporator unit 120.

As described above, FIGS. 7a and 7b depict an internal schematic of the condenser unit 130. In the preferred embodiment, the condenser unit 130 comprises a condenser coil 170 and a fan 172, wherein the fan 172 is connected to a fan bulkhead panel 176 which further comprises an air inlet to feed ambient air to the fan 172. In the preferred embodiment, the fan 172 pulls ambient air into the condenser unit 130, the ambient air passes through the condenser coil 170 and is discharged from the condenser unit 130. In an embodiment, the condenser coil 170 pulls heat from the refrigerant into the ambient air and discharges warm air from the condenser unit 130. In another embodiment, the condenser coil 170 pulls additional heat from the ambient air and warms the refrigerant. The connectors 154a, 154b (and optionally 154c) allow the condenser unit 130 to be operably connected to the compressor unit 110 and the evaporator unit 120.

The flexible tubing 156 used to operatively connect the compressor unit 110, evaporator unit 120, and, optionally, the condenser unit 130 assist with the flexibly arranging each of the units 110, 120, 130 in a variety of configurations.

Connectors and Flexible Tubing

The compressor unit 110, the evaporator unit 120, and optionally, the condenser unit 130 are operatively connected by means of connectors 154a, 154b, 154c and flexible tubing 156. The flexible tubing 156 allows the various units of the module to be placed in any configuration because the location of the condenser, compressor, and evaporator exist in distinct units. This allows the HVAC system to be configured into a variety of configurations. The connectors 154a, 154b, 154c and flexible tubing 156 may connect the compressor unit 110 to the evaporator unit only, or may also connect to the condenser unit 130.

In an embodiment, where the condenser unit 130 is in use with the compressor unit 110 and/or the evaporator unit 120, the system 100 uses flexible refrigerant tubing 156 to connect the connectors 154a, 154b, 154c of each of the units 110, 120, 130.

In an embodiment, when the condenser unit 130 is not in use with the compressor unit 110 and/or the evaporator unit 120, the flexible refrigerant tubing 156 is not required and the connectors 154a, 154b of both the compressor unit 110 and evaporator unit 120 connect directly to one another.

In an embodiment, when the condenser unit 130 is in use, three connections are formed: a first connection between a connector 154a of the compressor unit 110 and the connector 154a of the condenser unit 130, a second connection between a connector 154b of compressor unit 110 and a connector 154b (or 154c) of the evaporator unit, and a third connection between a connector 154b of the condenser unit and a connector of the evaporator unit 154a. These connections are made with the three flexible refrigerant tubes 156.

Connections Between HVAC Units

In an embodiment, a compressor unit 110 (as described above) may be connected to an evaporator unit 120 (as described above) in a frame to frame orientation. The compressor unit 110 and evaporator unit 120 attach at sides of the respective units 110, 120 that are not covered by a panel 114 and are aligned to facilitate an air pathway between the units 110, 120. In an embodiment the openings of the compressor unit 110 and evaporator unit 120 are partially obstructed by a reduced sized panel 114 that does not cover the entire opening.

In an embodiment, the compressor unit 110 may be connected to an evaporator unit 120 as described in the paragraph above. In addition, a condenser 130 (having a cubic frame perimeter) may be connected to another side of the evaporator unit 120 in a frame to frame orientation. If the evaporator 120 does not include a condenser coil 132, the condenser unit 130 and evaporator unit 120 attach at a remote panel 200 of the evaporator unit which connects to connectors 154 of the condenser unit 130 (which may likewise be disposed on a panel 114 of the condenser unit 130). In an alternative embodiment, the condenser 130 is operationally connected to, but disposed apart from, an evaporator unit 120. Tubing 156 connects the refrigerant inlet and outlet 202, 204 of the remote panel 200 of the evaporator unit 120 to the connectors 154 of the condenser unit 130.

In an embodiment, the compressor unit 110 may be connected to an evaporator unit 120 as described in the paragraphs above. In addition, a condenser 430 (having a triangular frame) may be operationally connected to, but disposed apart from an evaporator unit 120 (such as an evaporator unit 120 without a condenser coil 132). Tubing 156 connects the refrigerant inlet and outlet 202, 204 of the remote panel 200 of the evaporator unit 120 to the connectors 154a, 154b of the condenser unit 430.

In an embodiment, a mixing box 300 may be connected to an evaporator unit 120 in a frame to frame orientation. The mixing box 300 and evaporator unit 120 attach such that the filter housing 106 of the evaporator unit 120 is disposed within an opening 306 of the mixing box 300.

In alternative embodiments, other configurations which operatively connect the units 110, 120, 130, 430, and 300 are considered.

Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined in the appended claims. Having thus described in detail preferred embodiments of the present invention, it is to be understood that the invention defined by the above paragraphs is not to be limited to particular details set forth in the above description as many apparent variations thereof are possible without departing from the spirit or scope of the present invention.

Claims

1. A modular HVAC system comprising: an evaporator unit including a perimeter support structure defining a cubic frame having six openings;a compressor unit including a perimeter support structure defining a cubic frame having six openings;a first set of a plurality of panels selectively removably connected to the cubic frame of the compressor unit to cover five of the six openings and define a first uncovered opening, wherein one of the first set of plurality of panels includes an air discharge port;a second set of a plurality of panels selectively removably connected to the cubic frame of the evaporator unit to cover five of the six openings and define a second uncovered opening, wherein one of the second set of plurality of panels includes an air intake port;wherein the compressor unit and evaporator unit are detachably connected to align the first uncovered opening of the compressor unit and the second uncovered opening of the evaporator unit to define a system configuration.

2. The modular HVAC system of claim 1, wherein the system configuration is selectively one of thirty-six different configurations based on selection of the first uncovered opening and second uncovered opening.

3. The modular HVAC system of claim 1, further comprising a condenser unit operatively connected to the evaporator unit, the condenser unit including a perimeter support structure defining a frame of the condenser unit having a plurality of openings and a third set of a plurality of panels selectively removably connected to the frame of the condenser unit to cover the plurality of openings.

4. The modular HVAC system of claim 3, wherein the condenser unit comprises six openings.

5. The modular HVAC system of claim 4, wherein the third set of plurality of panels cover the six openings of the condenser unit, wherein one panel of the third set of plurality of panels is a first refrigerant panel comprising a refrigerant inlet and outlet, andwherein one panel of the second set of plurality of panels is a second refrigerant panel comprising a refrigerant inlet and outlet.

6. The modular HVAC system of claim 3, wherein the condenser unit and evaporator unit are detachably connected to align the first refrigerant panel of the condenser unit with the second refrigerant panel of the evaporator to define a condenser system configuration.

7. The modular HVAC system of claim 3, wherein the condenser unit comprises three openings and the third set of plurality of panels cover the three openings.

8. The modular HVAC system of claim 7, wherein one panel of the second set of plurality of panels is a second refrigerant panel comprising a refrigerant inlet and outlet and the condenser unit comprises a refrigerant inlet and outlet which detachably connect to the second refrigerant panel.

9. The modular HVAC system of claim 1, further comprising a mixing box unit, the mixing box unit further comprising: a perimeter support structure defining a cubic frame having six openings;a fourth set of a plurality of panels selectively removably connected to the cubic frame of the mixing box unit to cover five of the six openings and define a third uncovered opening, wherein two of the panels comprise dampening panels, the first dampening panel intaking ambient outdoor air and the second dampening panel intaking ambient indoor air;wherein the mixing box unit and evaporator unit are detachably connected to align a third uncovered opening of the mixing box and the panel of the evaporator unit having the air intake port to define a mixing box system configuration.

10. The modular HVAC system of claim 1, wherein the compressor unit and evaporator unit define an airflow pathway entering the air intake port disposed on the evaporator unit, moving through the first and second opening of the evaporator unit and compressor unit, and exiting the air discharge port disposed on the compressor unit.

11. The modular HVAC system of claim 1, wherein the panel of the evaporator unit having an air intake port is a filter panel, and the filter panel comprises a filter housing extending from the filter panel.

12. The modular HVAC system of claim 11, wherein the filter panel is oriented adjacent to a condenser coil apparatus disposed within a the cubic frame of the evaporator unit.

13. The modular HVAC system of claim 1, wherein one of the first set of the plurality of panels comprises an electrical panel having an electrical box, the electrical panel controlling power to the HVAC system and to internal components of the compressor unit and evaporator unit.

14. The modular HVAC system of claim 1, wherein the compressor unit comprises a plurality of internal components, the plurality of internal components comprising a compressor rack and a suction accumulator, wherein the plurality of internal components are detachably connected to a bottom frame rail of the compressor unit and extend upward from the bottom frame rail, the bottom frame rail being a rail of the cubic frame oriented along the lowest horizontal plane of the compressor unit.

15. The modular HVAC system of claim 1, wherein the evaporator unit comprises a plurality of internal components, the plurality of internal components comprising a condenser coil and a receiver, wherein the plurality of internal components are detachably connected to a bottom frame rail of the evaporator unit and extend upward from the bottom frame rail, the bottom frame rail being a rail of the cubic frame oriented along the lowest horizontal plane of the evaporator unit.