SYSTEMS AND METHODS FOR HVAC OUTDOOR UNIT WITH GRILL FORMING A SUPPORT STRUCTURE

Abstract

Systems and methods for heating, ventilation, and air conditioning (HVAC) systems with outdoor units having grills forming a support structure are provided. For example, an HVAC system may have an outdoor unit having a grill with vertical struts and horizontal struts which form one or more support structures, which may be in a rectangular shape for example. The support structure may receive a hook, clip, or other support portion of an HVAC maintenance device such as a refrigerant manifold gauge system or other HVAC gauge system. The support structure may be oriented in a direction perpendicular to a plane along which the grill extends, thereby avoiding any damage to the components of the outdoor unit by the maintenance device. The support structure and drill may be designed to withstand the weight of the maintenance device without deformation or damage.

Description

TECHNICAL FIELD

The present disclosure is generally in the field of heating, ventilation, and air conditioning (HVAC) systems. For example, systems and methods are provided herein for outdoor units of an HVAC system with a support structure.

BACKGROUND

Heating, ventilation, and air conditioning (HVAC) systems have been developed for heating and/or cooling both residential and commercial structures. For example, heat pump systems have been developed for heating and cooling residential structure and commercial structures. Similarly, HVAC systems such as air conditions have been developed for cooling residential and commercial structures. HVAC systems such as heat pumps and air conditioners typically include a refrigerant that is heated and/or cooled and circulated throughout the system to achieve heat transfer with the environment within the residential and/or commercial structure.

HVAC systems such as heat pumps and/or air conditioners often include components positioned within the residential or commercial structure, such as an indoor heat exchanger, as well as an outdoor unit which may include components positioned outside the structure. For example, as shown in FIG. 1, outdoor unit 100 may include housing 102 with grill 104, which may house an outdoor heat exchanger as well as a compressor. The outdoor heat exchanger may exchange thermal energy with the ambient environment via air flowing through grill 104.

To heat and/or cool the structure, refrigerant is circulated through the heat exchangers by the compressor and may also traverse an expansion valve. During installation and maintenance of the HVAC system, a refrigerant manifold gauge system or other HVAC gauge system (e.g., gauge system 150) may be connected to the system to ensure the HVAC system has an appropriate refrigerant volume and/or pressure for operation of the HVAC system. Typically, a technician will secure the refrigerant manifold gauge system or other HVAC gauge system to grill 104 of HVAC system 100. For example, a hook of gauge system 150 may be positioned through grill 104 to hang gauge system 150 on grill 104 and/or support gauge system 150.

Gauge system 150 is typically connected to several tubes and/or electrical wires that in addition to the weight of gauge system 150 itself create a significant downward force on grill 104. As grill 104 is not intended to support gauge system 150 in this manner, grill 104 may be deformed due to the weight of gauge system 150. Additionally, as the outdoor heat exchanger is often positioned directly behind the grill 104, inserting hook 155 or similar structure of gauge system 150 into grill 104 may damage such heat exchanger, which typically includes thin-walled coils or tubing and/or fins.

Accordingly, there is a need for improved methods and systems for HVAC systems capable of safely securing a gauge system or other maintenance device without damaging components of the HVAC system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of an outdoor unit of a heating, ventilation, and air conditioning (HVAC) system supporting a gauge system on a grill of the outdoor unit.

FIG. 2 is a schematic illustration of an HVAC system including an outdoor unit with a grill having a support structure, in accordance with one or more example embodiments of the disclosure.

FIG. 3 is a side view of an outdoor unit of an HVAC system having a grill with a support structure, in accordance with one or more example embodiments of the disclosure.

FIG. 4 is a schematic illustration of an outdoor unit of an HVAC system having a grill with a support structure supporting a gauge system, in accordance with one or more example embodiments of the disclosure.

FIGS. 5A-5B are schematic illustrations of grills for an outdoor unit of an HVAC system with pre-bent and bent support structures, in accordance with one or more example embodiments of the disclosure.

FIG. 6 is a schematic illustration of an outdoor unit of an HVAC system with a support structure with a triangular shape, in accordance with one or more example embodiments of the disclosure.

FIGS. 7A-7D are schematic illustrations of an outdoor unit of an HVAC system with a grill having a support structure, in accordance with one or more example embodiments of the disclosure.

DETAILED DESCRIPTION

Improved heating, ventilation, and air conditioning (HVAC) systems have been developed with an outdoor unit with a grill having a support structure for safely supporting maintenance devices such as a gauge system. The support structure may prevent deformation of the grill and/or damage to other components of the outdoor unit such as the heat exchanger. The outdoor unit may be an outdoor unit of a heat pump or air conditioning system, for example, and may include a housing supporting the grill and housing the heat exchanger and a compressor.

The heat exchanger and the compressor may be in fluid communication with HVAC system components positioned in a residential or commercial structure such as an indoor heat exchanger and/or expansion valve and together with the outdoor unit may heat and/or cool the residential or commercial structure. The grill may be designed to permit airflow to the heat exchanger in the outdoor unit and may be secured to the housing of the outdoor unit such that a downward force caused by the maintenance device does not damage the grill or components of the outdoor unit.

Referring now to FIG. 2, an HVAC system having an outdoor unit with a support structure is illustrated. Specifically, HVAC system 200 is illustrated including outdoor unit 212 and indoor portion 230. HVAC system 200 may be any HVAC system that may heat and/or cool a residential structure or commercial structure. For example, HVAC system 200 may be a heat pump or air conditioning system. Alternatively, HVAC system 200 may a heat pump water heater, or any other HVAC system.

As shown in FIG. 2, outdoor unit 212 may be positioned outside a residential or commercial structure, exposed to the ambient environment. HVAC system 200 may include indoor portion 230 which may include portions of the HVAC system which may be positioned within the residential or commercial structure. Outdoor unit 210 may be connected to indoor portion 230 via refrigerant lines, which may be designed to guide any suitable refrigerant between outdoor unit 212 and indoor portion 230.

Indoor portion 230 may include, for example, a heat exchanger that may receive the refrigerant from refrigerant lines 235 and may circulate the refrigerant through a plurality of coils and/or tubing to exchange thermal energy with the environment inside of the structure. Indoor portion 230 may further optionally include an expansion valve. Alternatively, the expansion valve may be positioned elsewhere.

Outdoor unit 212 may include housing 202, grill 204, compressor 210, heat exchanger 206, and/or fan 208. Alternatively, compressor 210 may be positioned elsewhere. Housing 202 may be any suitable housing structure designed to contain the components of outdoor unit 212 and protect such components from outdoor elements and/or conditions (e.g., weather, debris, animals, etc.). Housing 212 may include an opening (e.g., opening 205) which may be covered by grill 204.

Grill 204 may include a set of vertical struts and a set of horizontal struts, perpendicular to the vertical struts. However, it is understood that any suitable grill shape and/or design may be used (e.g., diamond pattern, circular pattern, etc.). Grill 204 may facilitate air flow through grill 204 such that air in the ambient outdoor environment may enter outdoor unit 212 and exchange thermal energy with heat exchanger 206.

Heat exchanger 206 may be similar to the heat exchanger of indoor portion 230. For example, heat exchanger 206 may receive the refrigerant from refrigerant lines 235 and may circulate the refrigerant through a plurality of coils and/or tubing to exchange thermal energy with the ambient environment outside the structure. Heat exchanger 206 may be positioned adjacent to grill 204 on an interior of outside unit 212.

Compressor 210 may be any compressor 210 suitable for compressing refrigerant and/or circulating fluid through heat exchanger 206 and the heat exchanger of indoor portion 230. It is understood that compressor 210 may be in fluid communication with heat exchanger 206 and the heat exchanger in indoor portion 230. Fan 208 may be any suitable fan or blower that may be positioned within housing 202 and may be designed to induce airflow through grill 204 to facilitate heat transfer with heat exchanger 206.

In the example illustrated in FIG. 2, grill 204 may include vertical struts (e.g., strut 224) and horizontal struts (e.g., strut 226). The vertical struts may be arranged in a parallel fashion and the horizontal struts may also be arranged in a parallel fashion, perpendicular to the vertical struts. The struts of grill 204 may form support structure 220 to support a maintenance device such as a refrigerant manifold gauge system or any other HVAC gauge system, or other HVAC maintenance and/or installation device.

As shown in FIG. 2, in one example, two horizontal struts (e.g., struts 226) that may or may not be adjacent to one another may be connected via support structure 220. For example, support structure 220 may be “C” or “bracket” shaped, rectangular, polygonal, “V” shaped, triangular, semi-circular/oval, or similar in shape. The support structure 220 may be a tubular structure that extends from the struts. In some embodiments, the support structure 220 is integral with the struts that it extends from, and may be bent, molded, or otherwise integrally formed from a portion of the struts that extends past the corresponding ends of adjacent struts. In another example, support structure 220 may be welded or otherwise coupled to the ends of two or more horizontal struts.

Support structure 220 may have a rectangular shape, with four corners, as shown in FIG. 2. Alternatively, support structure 220 may have any other shape (e.g., triangular, semi-circular/oval, polygonal shape). Support structure may extend in a direction or plane perpendicular to the planar orientation of grill 204 such that a maintenance device may hook, clip, or otherwise attach to support structure 220 without damaging grill 204, heat exchanger 206, and/or any other components of outdoor unit 212.

While FIG. 2 illustrates only one support structure, support structure 220, it is understood that multiple support structures may be included in grill 204. Additionally or alternatively, it is understood that support structure 220 may extend from vertical struts of grill 204 in a manner similar or identical to the above-described support structure extending from the horizontal struts. In one example, support structure 206 may be positioned near input/output ports for refrigerant lines 235 or any other access or service region of outdoor unit 212, to facilitate easy access for a maintenance device.

In some embodiments, the support structure is positioned at an upper region (e.g., proximal to the upper end) of the grill 204 or outdoor unit 212. In another example, the support structure may be positioned in a lower region (e.g., proximal to a base or bottom end of the outdoor unit) of grill 204 and/or may be positioned near a center region of grill 204. In yet another example, support structure 220 may optionally include a coating or other covering to increase the coefficient of friction of the material forming the surface of the support structure (e.g., to maintain a maintenance device in one position) or otherwise to reinforce the support structure. For example, support structure 220 may have an elastic or foam covering to facilitate stability of the maintenance device while attached to grill 204.

Horizontal struts 226 and/or vertical struts 224 may be connected or otherwise secured in a manner sufficient to safely support a maintenance device secured to the support structure without deforming, deflecting, or otherwise failing. For example, the grill, struts thereof, and support structure may be designed to support a maintenance device secured to the support structure weighing from 0.5 to 20 lbs, such as from 1 to 10 lbs, or from 2 to 5 lbs. In one example, vertical struts 226 and horizontal struts 224 may be welded or otherwise adhered using a suitable technique for achieving a rigidity and strength sufficient to support maintenance device at support structure 220.

It is understood that a greater or fewer number of components may be included in HVAC system 200. It is further understood that one or more components of FIG. 2 may be optional. Outdoor unit 212 may optionally include additional grills that may be the same as or similar to grill 204 (e.g., positioned on an opposite of outdoor unit 200), which may similarly include a support structure, which may be same as or similar to support structure 220.

Referring now to FIG. 3, a side view of an outdoor unit of an HVAC system with a support structure is depicted, in accordance with one or more example embodiments of the disclosure. For example, outdoor unit 312 may be the same as or similar to outdoor unit 212 of FIG. 2. As shown in FIG. 3, outdoor unit 312 may include housing 302, which may be the same as housing 202 of FIG. 2 and grill 304, which may be the same as grill 204 of FIG. 2.

Grill 304 may include support structure 320 which may be the same as support structure 220 of FIG. 2. Grill 304 may be a planar structure and may be oriented in a plane perpendicular to the plane and/or direction in which support structure 320 extends. In this manner, a hook or other support device of a maintenance device may be received by support structure 320 such that the maintenance device is supported by support structure 320. Because support structure extends away from the heat exchanger in the outdoor unit, maintenance device does not come into contact with the heat exchanger thereby avoiding any unintended contact.

Referring now to FIG. 4, a schematic illustration of an HVAC system with a support structure supporting a gauge system is depicted, in accordance with one or more example embodiments of the disclosure. For example, outdoor unit 412 may be the same as or similar to outdoor unit 212 of FIG. 2. As shown in FIG. 4, outdoor unit 412 may include housing 402, which may be the same as housing 202 of FIG. 2, heat exchanger 406, which may be the same as heat exchanger 206 of FIG. 2, and grill 404, which may be the same as grill 204 of FIG. 2.

Maintenance device 450, which may be the same as maintenance device 150 of FIG. 1, may be supported by support structure 420 extending from grill 404. As shown in FIG. 4, hook 452 may extend from maintenance device 450 and may rest at a corner (e.g., corner 452) of support structure 420. In one example, corner 452 of support structure 420 may be positioned lower than the rest of support structure 420 such that hook 452 or other structure of maintenance device 450 may be encouraged to rest at corner 454 by gravity.

Grill 404 may further include one or more eyelets for securing grill 404 and support structure 420 to housing 402. For example, eyelet 430 may extend from an end of strut 428. Housing 402 may include one or more holes (e.g., hole 436) for engaging and/or securing eyelet 430. For example, a threaded structure (e.g., screw) or a bolt-type structure may be inserted into eyelet 430 and received by hole 430 of housing 402 for securing grill 404 to housing 402. Eyelet 436 may then rigidly support the weight of maintenance device 450.

The support structure and grill may be designed to withstand the weight of the maintenance device without deformation or damage. For example, the gauge of the tube and/or rod may be sized to support the maintenance device. Additionally, the grill may be made from a suitable material for supporting the maintenance device (e.g., metal and/or plastic).

Referring now to FIGS. 5A-5B, schematic illustrations of grills of HVAC systems with pre-bent and bent support structures are illustrated, in accordance with one or more example embodiments of the disclosure. Grill 504 may be the same as or similar to grill 404 of FIG. 4. For example, grill 504 may include a grid pattern formed by a several vertical and horizontal struts. However, it is understood that grill 504 may be formed from struts forming any other pattern (e.g., diamond).

As shown in FIGS. 5A-5B, grill 504 may include vertical struts (e.g., vertical strut 524) oriented in a vertical direction and arranged in a parallel fashion and several horizontal struts (e.g., horizontal struts 526) oriented in a horizontal direction and arranged in a parallel fashion. Horizontal struts may be secured to vertical struts using any suitable technique (e.g., welding, adhesion, etc.).

Eyelets (e.g., eyelet 530) may be formed at the end of select struts. For example, every second, third, or fourth horizontal strut may include an eyelet at one or both ends. Alternatively, every strut may include an eyelet at one or more both ends. Eyelet 530 may be the same as or similar to eyelet 430 of FIG. 4. While only horizontal struts are illustrated in FIGS. 5A-5B having eyelets, it is understood that alternatively vertical struts alone or together with horizontal struts may include such eyelets at one or both ends of the horizontal struts.

Referring now to FIG. 5A, pre-bent support structure 538 is illustrated extending from and connecting two horizontal struts of FIG. 5A. As shown FIG. 5A, pre-bent support structure 538 may extend beyond other horizontal struts. Pre-bent support structure may extend along the same plane as grill 504. Pre-bent support structure 539 may be bent along bend line 539 to transition from a pre-bent orientation parallel to grill 504, to a bent orientation perpendicular to a plane along which grill 504 extends along.

Referring now to FIG. 5B, support structure 540 is illustrated extending along a plane or direction that is perpendicular to a plane along which grill 504 extends. For example, support structure 540 includes corners 551 at which support structure 540 was bent along bend line 549 of FIG. 5A. Support structure 540 may be the same as or similar to support structure 220 of FIG. 2.

Referring now to FIG. 6, a schematic illustration of an HVAC system with a support structure with a “V” or triangular shape is illustrated, in accordance with one or more example embodiments of the disclosure. Specifically, outdoor unit 612 may be the same as or similar to outdoor unit 412 of FIG. 4 and may include grill 604, which may be the similar to grill 404 of FIG. 4. However, instead of a rectangular shaped support structure, grill 604 may form support structure 620 which may be triangular in shape, having three corners.

FIGS. 7A-7D are schematic illustrations of an outdoor unit of an HVAC system with a grill having a support structure, in accordance with one or more example embodiments of the disclosure. The outdoor unit may have a grill 700 having a rectangular or loop support structure 700 that extends along an elongated face of the outdoor unit. In other embodiments, the support grill may be disposed along a lateral side of the outdoor unit.

Although embodiments have been described in language specific to structural features and/or methodological acts, it is to be understood that the disclosure is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as illustrative forms of implementing the embodiments. Conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments could include, while other embodiments do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments.

Claims

1. A system comprising: a first heat exchanger configured to receive a fluid;a second heat exchanger in fluid communication with the first heat exchanger via an expansion valve and configured to receive the fluid;a compressor in fluid communication with the first heat exchanger and the second heat exchanger;a fan configured to induce an airflow over the first heat exchanger;a housing configured to house the first heat exchanger, the fan, and the compressor within the housing, the housing having an opening adjacent to the first heat exchanger; anda grill sized and configured to cover the opening and having a first set of parallel struts in a first direction and a second set of parallel struts in a second direction perpendicular to the first direction, the first set of parallel struts and the second set of parallel struts oriented along a first plane,wherein a first and second strut of the first set of parallel struts are adjacent and connected at a first end of the first strut and a second end of the second strut via a support structure, the support structure oriented in third direction perpendicular to the first plane, the support structure configured to receive and support a maintenance device.

2. The system of claim 1, wherein the support structure is rectangular shaped having four corners.

3. The system of claim 1, wherein the support structure is configured to be bent to transition from an initial position orientated along the first plane to a final position oriented in the third direction.

4. The system of claim 1, wherein the support structure is a tubular structure and is configured to receive a hook of the maintenance device.

5. The system of claim 1, wherein the maintenance device is a refrigerant manifold gauge system or a heating, ventilation, and air conditioning (HVAC) gauge system.

6. The system of claim 1, wherein the support structure is configured to support the maintenance device without deformation of the support structure and without causing deformation of the grill.

7. The system of claim 1, wherein one or more struts of the first set of parallel struts comprises an eyelet for coupling the strut to the housing.

8. The system of claim 1, wherein one or more struts of the second set of parallel struts comprises an eyelet for coupling the strut to the housing.

9. The system of claim 1, further comprising an expansion valve in fluid communication with the first heat exchanger and the second heat exchanger, wherein the system is a heat pump or air conditioning system.

10. The system of claim 1, wherein the support structure is triangular shaped having three corners.

11. An outdoor unit of a heating, ventilation, and air conditioning (HVAC) system, the outdoor unit comprising: a first heat exchanger configured to receive a fluid;a compressor configured to circulate a fluid through the first heat exchanger;a fan configured to induce an airflow over the first heat exchanger;a housing configured to house the first heat exchanger, the fan, and the compressor within the housing, the housing having an opening adjacent to the first heat exchanger; anda grill sized and configured to cover the opening and having a first set of parallel struts in a first direction and a second set of parallel struts in a second direction perpendicular to the first direction, the first set of parallel struts and the second set of parallel struts oriented along a first plane,wherein a first and second strut of the first set of parallel struts are adjacent and connected at a first end of the first strut and a second end of the second strut via a support structure, the support structure oriented in third direction perpendicular to the first plane, the support structure configured to receive and support a maintenance device.

12. The outdoor unit of claim 11, wherein the support structure is rectangular shaped having four corners.

13. The outdoor unit of claim 11, wherein the support structure is configured to bend to transition from an initial position orientated along the first plane to a final position oriented in the third direction.

14. The outdoor unit of claim 11, wherein the support structure is a tubular structure and is configured to receive a hook structure of the maintenance device.

15. The outdoor unit of claim 11, wherein the maintenance device is a refrigerant manifold gauge system or an HVAC gauge system.

16. The outdoor unit of claim 11, wherein the support structure is configured to support the maintenance device without deformation of the support structure and without causing deformation of the grill.

17. The outdoor unit of claim 11, wherein one or more struts of the first set of parallel struts comprises an eyelet for coupling the strut to the housing.

18. The outdoor unit of claim 11, wherein one or more struts of the second set of parallel struts comprises an eyelet for coupling the strut to the housing.

19. The outdoor unit of claim 11, wherein the first heat exchanger is in fluid communication with a second heat exchanger via an expansion valve and the compressor is in fluid communication with the second heat exchanger.

20. The outdoor unit of claim 11, wherein the support structure is triangular shaped having three corners.