Abstract:
A receptacle box for conveniently and efficiently locating the terminal ends of the refrigeration line set, condensation drain and low voltage wires leading down from an air conditioner unit during initial construction of a building, is disclosed. Specifically, a rectangular box having a top, bottom, angled back, and sides, but open on the front, and having openings on the top through which the line set, condensation drain and low voltage wires can be passed, is disclosed. The receptacle box is mounted in a cutout on the exterior wall of the building before siding is installed.

Description:
[0001]    This application claims priority from U.S. provisional application No. 62/176,084 filed Feb. 4, 2015. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to a receptacle box for conveniently and efficiently locating the terminal ends of an air conditioner&#39;s refrigeration line set, condensation drain and low voltage wires leading down from the air conditioner unit during initial construction of a building. In particular, the present invention provides a more effective way for the refrigeration line set, condensation drain and low voltage wires to exit from the interior to the exterior of a building without using a fitting or being crushed, kinked or cut off after installation. 
         [0003]    When a building such as a home, office building or apartment building is first constructed, and is to have central air conditioning, the air conditioning unit is generally placed on an upper floor, attic space or roof of the building during the early stages of construction. At this time also the air conditioner&#39;s refrigeration line set, for compressed refrigerant and return, together with a condensation drain and low voltage electrical line, is connected to the air conditioner unit and leads down to the compressor unit which is placed at a lower level and outside the building. The line set, condensation tube and electrical line must therefore pass from the inside of the building through an outer wall and leave their ends accessible to be connected to corresponding lines coming from the condenser unit, which is installed later. 
         [0004]    As is now generally practiced in construction of new buildings, the line set, condensation drain and electrical line exit the wall through a simple hole cut in the wall. This frequently results in one or more of the lines being kinked, which can happen inside the wall, and create a cracked or clogged line resulting in an eventual refrigeration leak. Further, the ends of the lines and tubes are exposed and unprotected which can result in damage to the lines and drains, making it difficult to connect the compressor lines at a later date. Sometimes a fitting is employed to secure the lines on the outside wall, but this does not necessarily solve the problems. 
         [0005]    Presently, there is no device or system in use in either private or commercial buildings that provides for the efficient and safe exit of the refrigeration line set, condensation drain and low voltage wires through an external wall that can avoid kinks, cracks and clogs while also protecting the ends while the external wall is being constructed. 
       SUMMARY OF THE INVENTION 
       [0006]    A principle object of the present invention is to provide a device and a method to maintain the integrity of an air conditioner&#39;s line set, i.e., the refrigerant tube and return tube, condensation drain and low voltage electrical line, while exiting from an external wall while the building is under construction. It is an object of this invention to prevent kinking, cracking, bending or folding of the refrigeration line set, condensation drain and low voltage wires while exiting the external wall. It is also an object of the present invention to provide a device and a method to protect the ends of the refrigeration line set, condensation drain and low voltage wires once they have exited the wall so that they may be easily connected to the corresponding lines coming from the compressor when that unit is later installed. It is a further object of this invention to eliminate the need for a special exit fitting and to reduce the risk of a refrigerant leak within the external wall. 
         [0007]    Thus, according to these objectives, the system of the present invention employs a square or rectangular box that is installed on a new construction building before the siding is installed on the exterior wall. The box penetrates a pre-cut wall cavity so that the refrigeration tubing, condensation drain, low voltage wire, etc., has enough clearance to enter the top of the box which is top-scored for multiple sizes of holes and multiple tubing sets, that are easily cut out with a knife. The box&#39;s inner back wall is angled to allow the tubing to gradually exit the box while eliminating the need for a fitting. This configuration also allows the tubing to penetrate the exterior wall of the building without being kinked or crushed, reducing the risk of a refrigerant leak, or of being cut off after installation. The rear angular inner wall also allows water, such as from rain, to run out of the box. 
         [0008]    The condensation drain will have a straight run down the inside of the exterior wall of the building which also eliminates the need for a fitting at the exit point of the building where a crack or clog could occur inside the wall. The box also has a flange protruding outwards around the perimeter of the outside lip used as a nail flange for easy and secure installation. The outer lip extends far enough to allow the siding J-bead to be installed around the box and can be sealed weather tight to eliminate any water penetration. This method or installing refrigeration tubing, condensation drains and low voltage wiring saves many hours on installing the system. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    Referring to  FIGS. 1-6 , filed herewith, for details, dimensions and other specifications. 
           [0010]      FIG. 1  is a perspective view of an embodiment of this invention; 
           [0011]      FIG. 2  is a front view of a further embodiment of this invention; 
           [0012]      FIG. 3  is a top view of the embodiment of  FIG. 2 ; 
           [0013]      FIG. 4  is a back view of the embodiment of  FIG. 2 ; 
           [0014]      FIG. 5  is a bottom view of the embodiment of  FIG. 2 ; and 
           [0015]      FIG. 6  is a side view of the embodiment of  FIG. 2 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0016]    The preferred embodiments of the present invention will now be described with reference to the  FIGS. 1-6  of the drawings. Identical elements in the various figures are designated with the same reference numerals. 
         [0017]      FIG. 1  illustrates an embodiment of the device of the present invention, configured to accommodate two refrigeration line sets (not shown). The device comprises a box  100  for receiving the ends of a refrigerant tube and return tube (not shown), together referred to as the “line set,” from an air conditioner unit. Box  100  therefore may also be referred to herein as “line set box  100 ,” Line set box  100  in  FIG. 1  is also designed to receive the ends of two condensation drains (not shown), from the air conditioner unit as well as two low voltage electrical lines (not shown), that connect to the air conditioner unit. As shown in  FIG. 1 , line set box  100  is configured as an open-sided box that can be either square or rectangular in shape. Accordingly, line set box  100  has a top side  105 , a left side  110  and a right side  115 , a back  120  and a bottom side  125 . Where a box would ordinarily have a corresponding “front side” opposite to its back, in line set box  100  the front side opposite back  120  is not present, the front being left open. Thus, line set box  100 , having an open side, allows for access to the ends of the refrigeration line set, condensation drain and low voltage line once they have entered the line set box  100  through top side  105 . 
         [0018]    Constructed of a durable plastic polymer, such as polypropylene, or stamped from an appropriate metal, line set box  100  has a width dimension  130 , a height dimension  135  and a depth dimension  140 . Although these dimensions can vary according to the size of the line set box desired, for example, when single or multiple line sets are required, in this embodiment the preferred that width dimension  130 , which can be between about 4.5″ to about 12″, is about 10″, height dimension  135  which can be between about 10″ to about 14″ is about 11″, and depth dimension  140 , which can be between about 3.5″ to about 6″, is about 4.5″. Around the periphery of line set box  100 , and towards the front, is located a flange  145  for nailing the line set box to an opening pre-cut into the outer wall  300  of the building (see  FIG. 5 ), prior to the siding being added to the building. Nail flange  145  can be from about 0.5″ to about 2″ wide, and preferably is about 0.75″ wide. Accordingly, nail flange  145  is not placed at the outer edge of line set box  100 , but is located about 0.75″ from the rim  150  of line set box  100 , to allow space for when the building&#39;s siding is added. Thus, when line set box  100  is properly mounted in the pre-cut opening, approximately 0.75″ of the box extends outward from the wall, and the remaining about 3.5″ extends toward the interior of the wall. In addition, rim  150  is configured in the form of a “J-bead” to allow for attachment of trim features that are part of the siding. 
         [0019]      FIG. 1  also illustrates the configuration of back  120  and bottom  125 , which are not joined at a 90° angle as is typical of an ordinary box. Rather, bottom  125  is angled upward from its leading edge until it meets with back  120 , where it is joined. The upward angle  122  of bottom  20  can be generally from about 20° to about 60°, and about 45° is preferred. Being angled in this manner, bottom  125  directs the line set, condensation drain and low voltage line in a gentle are away from back  120  and the building wall, to the outside of line set box  100  and the building itself. In this manner, kinks, cracks and leaks are minimized if not avoided altogether. In addition, the angling of bottom  125  allows for the drainage of water from the box  100 , as caused by rain, for example. Once inside of line set box  100 , the line set, condensation drain and low voltage lines are “capped” and are thus further protected until the air conditioner compressor unit is installed. 
         [0020]    As also illustrated in  FIGS. 1 , top side  105  contains circular cut-outs  155  which, when removed, allow for the passage of the refrigeration line set and low voltage line into box  100 . Cut-outs  155  are comprised of concentric discs  160  and  165 , which can be punched out to allow for different diameters of tubing. Generally, the outside disc  160  can have a diameter of about 2.5″ which normally would accommodate the refrigeration line set and low voltage line. The inner disc  165  has a smaller diameter for allowing other size of tubes or wires as desired. Top side  105  may also contain smaller circular cut-outs  170 , which are shown as being located between cut-outs  155 . This is for purposes of illustration only as cut-outs  155  and smaller cut outs  170  may be located in any desired position on top side  105 . Smaller cut-outs  170  are configured as having a smaller diameter than cut-outs  155  and are more particularly designed for the condensation drain and low voltage electrical line. The diameter of smaller circular cut outs  170  may vary, but is preferably about 0.75″. 
         [0021]    A further embodiment of the within invention is depicted by  FIGS. 2-6 , with  FIG. 2  being a front view. In this embodiment, line set box  100  is designed for a single air conditioner unit which has only a single refrigeration line set, including low voltage line, and a single condensation drain. Specifically referring to  FIG. 3  it can be seen that top  105  of line set box  100  in this embodiment contains only a single cut out  155  for the refrigeration line set and low voltage line, and a single smaller cut out  170  for the condensation drain. Here, however, it can also be seen that smaller cut out  170  may also have concentric discs  175  and  180 , so that different size drain tubes or other lines may be accommodated. 
         [0022]    The embodiment of  FIGS. 2-6  also has a narrower width dimension  130  than the embodiment of  FIG. 1 . Specifically, width dimension  130  of this embodiment can range from about 4.5″ to about 6.5″ with about 5.75″ being preferred.  FIGS. 2 and 4  also illustrate nail holes  195  for placement of nails through flange to secure line set box  100  to wall  300 . 
         [0023]    In addition,  FIG. 2  illustrates a further distinction between the embodiment of  FIG. 1 . Rather than having bottom  125  angled to meet back  120  as in  FIG. 1 , the embodiment of  FIG. 2  has a bottom configured as an upper bottom piece  185  and a lower bottom piece  190 . Upper bottom piece  185  and lower bottom piece  190  combine together to replace back  125  and join back  120  as shown more clearly in  FIG. 6 . The angles at which back  120 , upper bottom piece  185  and a lower bottom piece  190  are joined may vary, although overall angle  122  is maintained as described above for  FIG. 1 . Having upper bottom piece  185  and lower bottom piece  190  provides more space in the back of line set box  100  for the line set and condensation drain, and also allows for a gentler arc in directing the line sets, voltage lines and drains to exit from the open front on box  100 . 
         [0024]      FIG. 5  illustrates the bottom of line set box  100 , in which only upper bottom piece  185  and a lower bottom piece  190  can be seen from this view. 
         [0025]    In conjunction with the disclosure of the line set box  100  of this invention is a method for providing an effective way for the refrigeration line set, condensation drain and low voltage wires to exit from the interior to the exterior of a building without using a fitting or being crushed, kinked or cut off after installation. The method comprises the steps of pre-cutting a square or rectangular hole in the outside wall of the building, before siding is added, and installing line set box  100  by nailing it onto the outside of the wall  300  using the nail flange  145 . Cut outs  155  and  170  are then opened using an appropriate tool, such as a knife. Then, the refrigeration line set, low voltage wire and condensation drain from the above-installed air conditioner unit, are channeled down the inside of external wall  300 , through cut outs  155  and  170 , and into line set box  100 . Specifically, the refrigeration line set is channeled through larger cut out  155 , and is followed by low voltage wire, also through cut out  155 . The condensation drain is channeled through smaller cut out  170 . Once inside line set box  100 , the ends of the refrigeration line set, condensation drain and low voltage wires are covered or capped, to protect them until they can be connected to the corresponding lines of the compressor unit of the air conditioner. 
         [0026]    The preceding preferred embodiments are illustrative of the practice of the invention. It is to be understood, however, that other expedients known to those of skill in the art, or disclosed herein, may be employed without departing from the spirit of the invention or the scope of the claims.