The present disclosure relates generally to air conditioning systems, and more particularly to drainage maintenance of packaged terminal air conditioning (PTAC) units.
Air conditioning systems are in widespread use and are provided in two general arrangements. There are “split” systems where the evaporator unit is located indoors, and the compressor unit is located outside, with refrigerant lines connecting the two units through a wall of the structure. There are also self-contained units that package the evaporator and compressor together in one unit. Some self-contained air conditioning (A/C) systems are designed to be mounted in a window, and other similar A/C units are designed to be mounted in a through-wall opening. A common self-contained A/C unit configuration is the packaged terminal air conditioner (PTAC), which are commonly used in hotel rooms, and similar multi-occupancy structures. As with all A/C systems, the evaporator unit chills air that is drawn or blown over the evaporator coil by a fan, resulting in moisture vapor in the warm air condensing and accumulating on the coil, where it collects and runs into a pan, and drains through a drain hole into a drainage line. In some arrangements, the water is simply routed to an outside port of the PTAC unit, allowing it to drip out. In some applications the cold water is used to cool the condenser coil by routing collected condensate to the condenser portion of the unit, and a fan can splash the water onto the condenser coil.
The high moisture environment inside of a PTAC unit is highly conducive to the growth of certain molds, algae, and other microbial growth. Over time, this growth can obstruct the drain, causing a blockage, resulting in an overflow of water into the interior of the structure, resulting in water damage and potentially giving rise to other forms of mold growth in the building structure. Accordingly, property owners want to avoid the cost of repairs due to water damage caused by overflowing A/C units. This is especially problematic in self-contained A/C units because the drain pan is typically designed to hold some water to cool the coil of the compressor unit.
The problem of microbial growth in PTAC units is treated as a maintenance issue, and to prevent drain blockage from occurring, chemicals are periodically introduced into the drain pan to kill or suppress microbial growth. Chemical treatment is typically accomplished by the use of slow dissolving tablets that are placed in the drain pan. These tablets slowly dissolve in the condensate water, which creates a solution that flows into the drain, killing and inhibiting growth. However, to put these tablets into the drain pan, the PTAC unit must be taken apart by removing the chassis from the wall sleeve in order to access the interior and place the tablets in the drain pan. Although the tablets only need to be added once every several weeks or so, because of the difficulty and inconvenience involved, PTAC units often go untreated for too long, or not at all. It isn't until leakage is noticed that the drain blockage is recognized.
Therefore, a need exists to overcome the problems with the prior art as discussed above.
In accordance with the inventive disclosure there is provided, in some embodiments, a method for inhibiting microbial growth in a packaged terminal air conditioner (PTAC) that includes providing a wall sleeve for the PTAC that is configured to receive a chassis. The chassis has a chassis drain pan, and the wall sleeve has a bottom that includes a drain reservoir. The wall sleeve has a side wall that has an exterior side and an interior side. There is a first aperture formed through the side wall, and a first guide structure is disposed on an inside of the side wall at the interior side and has a receiving portion positioned in correspondence with the first aperture, and also has a lower portion arranged in a position over the bottom of the wall sleeve. The method further includes inserting, through the first aperture, a spheroid treatment pellet, wherein the guide structure is configured to direct the spheroid treatment pellet to the drain reservoir.
In accordance with a further feature, inserting the spheroid treatment pellet comprises inserting a belted spheroid treatment pellet.
In accordance with a further feature, providing the wall sleeve further comprises providing the wall sleeve having a sloped bottom wherein the sloped bottom is configured to direct water across the sloped bottom to the drain reservoir.
In accordance with a further feature, providing the wall sleeve having a sloped bottom comprises providing a sloped insert into the bottom of the wall sleeve to form the bottom of the wall sleeve.
In accordance with a further feature, providing the wall sleeve having the first guide structure comprises providing the wall sleeve having the first guide structure comprising a tube that extends from the first aperture to the drain reservoir.
In accordance with a further feature, providing the tube that extends from the first aperture to the drain reservoir includes providing the tube having notches at a distal end of the tube that is positioned in the drain reservoir, wherein the notches are smaller than the spheroid treatment pellet in an undissolved state.
In accordance with a further feature, providing the wall sleeve having the first guide structure comprises providing the wall sleeve having the first guide structure comprising a vertical down section having a ramp end that is configured to direct the spheroid treatment pellet to roll across the bottom of the wall sleeve to the drain reservoir.
In accordance with a further feature, the method further includes providing the wall sleeve having a second aperture formed through the sidewall, and a second guide structure disposed on an inside of the side wall at the interior side and having a receiving portion positioned in correspondence with the second aperture and a lower portion arranged in a position over the chassis drain pan.
In accordance with the inventive disclosure there is provided, in some embodiments, a wall sleeve for a packaged terminal air conditioner (PTAC) that is configured to receive a chassis in which a compressor unit and an evaporator unit are provided. The chassis includes a chassis drain pan, and the wall sleeve has a bottom that includes a drain reservoir. The wall sleeve includes a front having an opening through which the chassis can be placed to mount the chassis in the wall sleeve, and a side wall having an exterior side and an interior side. There is a first aperture formed through the side wall. There is also a first guide structure disposed on an inside of the side wall at the interior side that has a receiving portion positioned in correspondence with the first aperture and a lower portion arranged in a position over the bottom of the wall sleeve.
In accordance with a further feature, the wall sleeve having a sloped bottom wherein the sloped bottom is configured to direct water across the sloped bottom to the drain reservoir.
In accordance with a further feature, the bottom of the wall sleeve is formed by a sloped insert disposed into the wall sleeve.
In accordance with a further feature, the first guide structure comprises a tube that extends from the first aperture to the drain reservoir and has a distal end positioned in the drain reservoir.
In accordance with a further feature, there is further included notches formed at the distal end of the tube.
In accordance with a further feature, the first guide structure comprises a vertical down section having a ramp end that is configured to direct a spheroid treatment pellet across the bottom of the wall sleeve to the drain reservoir.
In accordance with a further feature, the wall sleeve further has a second aperture formed through the sidewall, and the wall sleeve further includes a second guide structure disposed on an inside of the side wall at the interior side and having a receiving portion positioned in correspondence with the second aperture and a lower portion arranged in a position over the chassis drain pan.
In accordance with the inventive disclosure there is provided, in some embodiments, a treatment pellet that includes a spheroid body made of a water soluble material including a component that inhibits microbial growth. The spheroid body is sized to fit in a guide structure mounted in a wall sleeve of a packaged terminal air conditioner (PTAC) that directs the treatment pellet to one of a chassis drain pan or a bottom of the wall sleeve.
In accordance with a further feature, the spheroid body a hemispherical top portion, a hemispherical bottom portion, and a cylindrical section that forms a belt around the spheroid body and joins the hemispherical top portion and the hemispherical bottom portion. The hemispherical top portion and hemispherical bottom portion are oriented in opposing directions with respect to each other and are disposed on opposite sides of the cylindrical section. A height between peaks of the hemispherical top portion and the hemispherical bottom portion is less than a diameter of the cylindrical section.
Although the disclosure is illustrated and described herein as embodied in a wall sleeve for a packaged terminal air conditioner unit and a packaged terminal air conditioner unit using the wall sleeve, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the disclosure and within the scope and range of equivalents of the claims. Additionally, well-known elements of exemplary embodiments of the disclosure will not be described in detail or will be omitted so as not to obscure the relevant details of the disclosure.
Other features that are considered as characteristic for the disclosure are set forth in the appended claims. As required, detailed embodiments of the present disclosure are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to variously employ the present disclosure in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the disclosure. While the specification concludes with claims defining the features of the disclosure that are regarded as novel, it is believed that the disclosure will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward. The figures of the drawings are not drawn to scale.
Before the present disclosure is disclosed and described, it is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. The terms “a” or “an,” as used herein, are defined as one or more than one. The term “plurality,” as used herein, is defined as two or more than two. The term “another,” as used herein, is defined as at least a second or more. The terms “including” and/or “having,” as used herein, are defined as comprising (i.e., open language). The term “coupled,” as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically. The term “providing” is defined herein in its broadest sense, e.g., bringing/coming into physical existence, making available, and/or supplying to someone or something, in whole or in multiple parts at once or over a period of time.
“In the description of the embodiments of the present disclosure, unless otherwise specified, azimuth or positional relationships indicated by terms such as “up”, “down”, “left”, “right”, “inside”, “outside”, “front”, “back”, “head”, “tail” and so on, are azimuth or positional relationships based on the drawings, which are only to facilitate description of the embodiments of the present disclosure and simplify the description, but not to indicate or imply that the devices or components must have a specific azimuth, or be constructed or operated in the specific azimuth, which thus cannot be understood as a limitation to the embodiments of the present disclosure. Furthermore, terms such as “first”, “second”, “third” and so on are only used for descriptive purposes, and cannot be construed as indicating or implying relative importance.
In the description of the embodiments of the present disclosure, it should be noted that, unless otherwise clearly defined and limited, terms such as “installed”, “coupled”, “connected” should be broadly interpreted, for example, it may be fixedly connected, or may be detachably connected, or integrally connected; it may be mechanically connected, or may be electrically connected; it may be directly connected, or may be indirectly connected via an intermediate medium. As used herein, the terms “about” or “approximately” apply to all numeric values, whether or not explicitly indicated. These terms generally refer to a range of numbers that one of skill in the art would consider equivalent to the recited values (i.e., having the same function or result). In many instances these terms may include numbers that are rounded to the nearest significant figure. Those skilled in the art can understand the specific meanings of the above-mentioned terms in the embodiments of the present disclosure according to the specific circumstances.
The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and explain various principles and advantages all in accordance with the present disclosure.
While the specification concludes with claims defining the features of the disclosure that are regarded as novel, it is believed that the disclosure will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward. It is to be understood that the disclosed embodiments are merely exemplary of the disclosure, which can be embodied in various forms.
The present disclosure provides a novel and efficient self-contained air conditioner unit that allows drainage maintenance to be performed without having to take the air conditioner unit apart or disassemble any portion of the air conditioner unit. Embodiments of the disclosure provide a self-contained air conditioner unit suitable for a through-wall or in window application where the air conditioner unit provides access-ways that allow a person to place anti-microbial treatment pellets into the internal drain pan(s) of the unit, as well providing directed access to the drain line in units that are more permanently installed.
The chassis 104 has a front portion that sits inside the room and is covered by a housing 106, while the section including the condenser coil 120 is located in the back of the chassis 104 so that air from outside can be blown over the condenser coil 120 to remove heat from the compressed refrigerant in the condenser coil 120. Typically the back of the chassis 104 is covered with a louvre panel (not shown), as is known. When the PTAC is operating in a cooling mode, moisture that is in the air inside the room will condense on the evaporator coil. As the condensate collects it is routed to a drain to prevent water leaking out of the unit. It is common to use a chassis drain pan 118 to collect some of the condensate, and use the collected cold water to help cool the condenser coil 120. For example, the chassis drain pan 118 is typically arranged to collect water to a selected depth that allows the blades of the fan blowing air over the condenser coil 120 to splash water into the condenser coil 120. However, because the water then has to rise to selected drain level, some of the water stagnates in the chassis drain pan 118, allowing microbial growth to occur, which can clog the drainage path.
Typically the chassis drain pan 118 drains into a wall sleeve drain pan 108, which is essentially the bottom of the wall sleeve 102. A drain hole 110 can be formed through the bottom of the wall sleeve drain pan 108, and it is either connected to a drainage, or configured to drain out the rear of the unit (e.g. outside). Further, the wall sleeve drain pan 108 can have raised features 122 stamped or formed therein on which the bottom of the chassis 104 sits, providing space between the bottom of the chassis 104 and the wall sleeve drain pan 108.
In a conventional PTAC unit, the cover 106 and chassis 104 must be removed, at least partially, from the wall sleeve 102 in order to add treatment pellets to inhibit microbial growth in the drain pans 108, 118. Treatment pellets are formed of a chemical compound that dissolves slowly in water, and which then dissipates throughout the collected water, and into the drain, and can be formed in a variety of shapes and sizes, including, for example, spheres, belted spheres, disks, cylinders, and so on. Treatment pellets need to be added periodically since they dissolve and the flow of water dilutes the Accordingly, it is common to establish a schedule for adding treatment pellets to the PTAC units in a facility like a hotel. However, the personnel tasked with doing so often find it difficult to take the PTAC units apart, as the chassis can be quite heavy, and care has to be taken to not spill water that may be sitting in the chassis drain pan 118. As a result, personnel sometimes neglect to perform the process of depositing treatment pellets into the PTAC units, or some PTAC units.
In order to simplify the task of putting treatment pellets into a PTAC unit, one or more openings such as apertures or openings 112, 114, 116 can be formed through a sidewall 124 of the wall sleeve 102 at a location that, when the wall sleeve 102 is installed in a wall, is exposed inside the room (e.g. a portion of the wall sleeve 102 that extends forward from the wall). However, the opening or openings are positioned such that they are not obscured by components in the chassis 104 or part of the chassis 104. On the inside of the wall sleeve 104, as will be shown in subsequent drawings, in correspondence with each opening 112, 114, 116 is a guide structure. Some of the guide structures are configured to guide a treatment pellet that is inserted into the corresponding opening to a desired location inside the PTAC unit 100. For example, aperture 112 can correspond to a guide structure that is configured to guide a treatment pellet into the chassis drain pan 118. Likewise, aperture 116 can correspond to the guide structure that is configured to guide a treatment pellet between the chassis drain pan 118 and the inside of the side wall 124 into the wall sleeve drain pan 108. A third aperture 114 can correspond to a guide structure that is configured to guide a drain snake to the drain 110 of the wall sleeve drain pan to allow servicing of the drain with the drain snake. Thus, once the PTAC unit 100 is assembled, with the chassis 104 mounted in the wall sleeve 102, maintenance personnel will no longer have to pull the chassis 104 out of the wall sleeve 102 in order to place treatment pellets into the unit. In some embodiments a cover structure can be provide on the outside of the side wall 124 that is moveable, and which covers the opening(s) 112, 114, 116 so as to prevent any undesired object or debris from getting into the unit 100.
Attached to, or mounted on the inside 212 of the sidewall 208 of the wall sleeve 202 are several guide structures 206, 220. The guide structures 206, 220 are provided such that their upper portions 214 each correspond to a respective aperture or opening (e.g. 112, 114, 116) through the sidewall 208. A first guide structure 206 can be in the form of a tube that is bent at an angle at the top portion 214. A lower portion 216 extends outward and downward such that a lower opening 218 is positioned over the chassis drain pan 204. Thus, when a treatment pellet is inserted into the corresponding opening through the sidewall 202, the treatment pellet is guided by the first guide structure 206 such that gravity moves the treatment pellet downward through the guide structure 206 until the treatment pellet falls into the chassis drain pan 204. Thus, the PTAC unit does not need to be taken apart in order to place treatment pellets (or tablets, liquids, etc.) into the chassis drain pan 204.
A second guide structure 220, having its top portion mounted in correspondence with a second opening through the sidewall 208, is configured to guide a treatment pellet from the second opening, upon insertion of the treatment pellet through the second opening, into the wall sleeve drain pan, formed by the bottom 205 of the wall sleeve 202, through gap 224. The lower portion 222 of the second guide structure 220 is configured such that anything passing through the guide structure 220 will fall past the chassis drain pan 204 and to the bottom 205 of the wall sleeve 202. In some embodiments both the first and second guide structures 206, 220 can be made of sections of copper tubing such as that commonly used in plumbing applications. In some embodiments the guide structures 206, 220 can be made of plastic tubing or piping, such as polyvinyl chloride (PVC) piping.
The wall sleeve 500 has first sidewall 502 that has an inside or interior surface 504. The wall sleeve 500 further includes a bottom 506, a second sidewall 505 and a top 507. The bottom 506 includes a drain opening 508, and the bottom 506 can be shaped to slope slightly downward from the sides to the drain opening 508 from the perimeter of bottom 506 to facilitate drainage. In some embodiments the edge of the drain hole 508 can be about one half inch to one and one half inches below the edges of the bottom 506, where the bottom 506 meets the sides. When the chassis is mounted into the wall sleeve 500, overflow from the chassis drain pan can drain into the bottom 506 of the wall sleeve 500 and through the drain hole 508 into a drain pipe. In some embodiments, however, water can be drained directly through the back/outside of the wall sleeve 500 to the outside environment.
The first sidewall 502 has several openings or apertures formed through the first sidewall from an exterior to the interior. There are several guide structures 510, 512, 514 which each have an end positioned in correspondence with a respective one of the several openings through the first sidewall 502. Guide structure 510 can be a tube that is configured to be against, or in sufficient proximity to the bottom 506 of the wall sleeve 500 to be under the chassis when the chassis is mounted in the wall sleeve, and traverses across the wall sleeve 500 from the interior 504 of the first sidewall 502 at an opening to the bottom 506, and across the bottom 506 to the drain hole 508. The end of the guide structure 510 at the drain hole 508 is turned downward to direct anything passing through guide structure 510 into the drain through drain hole 508. For example, a drain snake can be passed from the outside of the PTAC unit through the opening corresponding to the guide structure 510, and through the guide structure 510 into the drain pipe through the drain hole 508 in order to clean out the drain pipe and dislodge any material that may be blocking the drain. Further, drain maintenance liquids (e.g. “drain de-clogger”) can be poured through guide structure 510 directly into the drainage line. These maintenance operations can be performed without having to disassemble the PTAC unit.
Likewise another guide structure 512 can be configured to have a free end disposed over the chassis drain pan when the chassis is mounted in the wall sleeve 500, and is mounted on the interior 504 of the first side wall 502 of the wall sleeve at an aperture through the sidewall 502. Thus, guide structure 512 allows a person to deposit a treatment pellet into the chassis drain pan by inserting the treatment pellet into the aperture through the sidewall 502 corresponding to the guide structure 512, whereupon gravity will draw the treatment pellet down and through the guide structure 512 where the treatment pellet will fall into the chassis drain pan. Another guide structure 514 is configured to direct treatment pellets from yet another aperture through the sidewall 502 into the wall sleeve bottom 506, which acts as a wall sleeve drain pan. Guide structure 514 is similar to guide structure 220 of
Guide structures 510, 512, 514, 516 are mounted on the interior 504 of the first side wall in a position so that the chassis of the PTAC unit can be moved in and out of the wall sleeve 500 without the guide structures 510, 512, 514, 516 snagging or interfering with the movement of the chassis in or out of the wall sleeve 500. In particular, guide structure 512, which extends over the chassis drain pan when the chassis in mounted in the wall sleeve 500, does not extend far enough into the interior space of the wall sleeve that it will be in the way of components on the chassis when the chassis is moved into or out of the wall sleeve 500. Accordingly, components on the chassis have to be configured such that there is clearance for the guide structure 512, and that the chassis drain pan will be under the lower end of guide structure 512.
The cover 702 can be a flat member that is attached to the sidewall 700 at a pivot point 704 that allows the cover 702 to move about the pivot point 704 as indicated by arrows 706. The pivot point is located directly over the aperture 708 and the cover 702 hangs on the pivot point 704 such that it naturally covers the aperture 708 unless moved to the side (i.e. in the direction of arrow 706). The cover 702 prevents debris and other objects from entering the PTAC unit. When a treatment pellet is to be provided into the PTAC unit, the cover 702 can be moved by pivoting it around the pivot point 704 to reveal the aperture 708, thereby allowing a treatment pellet to be inserted into the opening 708. The pivot point 704 can be a rivet or similar feature that attaches to the sidewall 700. Other forms of covers can be used equivalently, including, for example, a flap that hangs over the aperture 708 or several apertures, having a bottom that lifts up and away from the sidewall.
In testing the process, however, it was found that creating a perfectly spherical treatment pellet is difficult and a significant number of mold positions fail to produce a sufficiently compacted unit to retain the spherical shape. The provision of a cylindrical section around the middle of the unit—a belt—greatly increases the yield in molding treatment pellets and produces a pellet that can still roll sufficiently to reach the reservoir in the drain pan.
As shown, each belted spheroid treatment pellet 2000 includes a hemispherical top portion 2002 and a hemispherical bottom portion 2004. The two hemispherical portions 2002, 2004 are oriented in opposing directions and are joined to a central cylindrical section 2006 that forms a belt around the belted spheroid treatment pellet 2000. The pellet 2000 is made of a water soluble material that inhibits the growth of various microbes known to grow in air conditioner units. The radius 2014 of the hemispherical portions 2002, 2004 can be greater than half a diameter 2016 of the pellet 2000. In some embodiments the radius 2014 of the hemispherical portions 2002, 2004 can be in the range of 0.15 to 0.25 inches, or more or less than that in some embodiments. The diameter 2016 can be on the order of 0.35 to 0.45 inches in some embodiments, and more or less than that in some embodiments. The belt height 2010 can be in the range of 0.08 to 0.12 inches in some embodiments, and more or less than that in some embodiments. The height of the hemispherical portions 2002, 2004 from the belt 2006 can be in the range of 0.09 to 0.13 inches in some embodiments, and more or less than that in some embodiments. In some embodiments the cylindrical belt section 2006 can extend outward from the hemispherical portions 2002, 2004 to create a land that has a width of 0.004 to 0.008 inches in some embodiments, and more or less than that in some embodiments. In some embodiments the pellet 2000 can have the following dimensions, with a toleration of +/−0.003 inches: diameter 2016 of 0.375 inches, belt height 2010 of 0.107 inches, hemispherical portion height 2008 of 0.119 inches, and land width 2018 of 0.006 inches. A height 2012 between the peaks of the hemispherical portions 2002, 2004 can be less than a diameter 2016 of the cylindrical section 2006.
Although the belted spheroid pellet 2000 is not perfectly spherical, when dropped through a guide structure such as second guide structure 1906 of
By sloping the bottom if the drain pan 2000, water will only stand in the bottom of the reservoir 2102. As a result, a volume of water on the order of ounces may be retained, rather than closer to a gallon in some prior art PTAC units. As microbial growth can occur where there is sufficient water, it is desirable to treat the drain reservoir 2102 in order to inhibit, if not prevent microbial growth. A treatment pellet 2000 can be inserted through the side 816 of the wall sleeve into the second guide structure 1906 to follow a path indicated by dashed arrow. As the pellet 2000 follows the shape of the second guide structure 1906 in a mostly vertical direction it gains velocity, and is then guided to more of a horizontal direction by the ramp end 1908. The pellet 2000 will then roll across the bottom 2101 into the reservoir 2102 where it will slowly dissolve in water, thereby distributing the microbial growth inhibiting material into the standing water in the drain reservoir 2102 and into the drain.
A wall sleeve for a PTAC unit and a PTAC unit using the wall sleeve has been described that provides an external access port coupled with internally mounted guide structures that allow the provision of treatment pellets into the internal drain pan(s) of the PTAC unit without having to disassemble the PTAC unit. The embodiments of the inventive disclosure greatly simplifies routine maintenance to prevent growth and build-up of microbial matter than can foul internal components of the PTAC unit, which can reduce efficiency, and which can further block or obstruct drainage, resulting in leakage outside of the air conditioner unit that can damage interior structure, facilitate mold growth, and other issues associated with water leakage. By providing a simple and easy way to place treatment pellets into the PTAC unit, the PTAC unit does not have to be partially disassembled to place treatment pellets into the PTAC unit drain structures. This helps ensure that regular maintenance of PTAC units will be followed, and it greatly reduces the time needed to perform such maintenance.
This application is a continuation in part of U.S. application Ser. No. 16/665,205, filed Oct. 28, 2019, titled “Packaged Terminal Air Conditioner System and Sleeve Therefor,” which claimed the benefit of U.S. Provisional Application No. 62/866,788, filed Jun. 26, 2019, the entireties of each of which are hereby incorporated by reference.
Number | Date | Country | |
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62866788 | Jun 2019 | US |
Number | Date | Country | |
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Parent | 16665205 | Oct 2019 | US |
Child | 16996436 | US |