Abstract:
The present invention relates to a modular air conditioning unit, comprising a chassis having an outside surface, comprising an evaporator coil air intake opening; a treated air discharge opening; and a condenser coil air intake opening; and an air conditioning system located within the chassis, comprising a condenser coil unit, an evaporator coil unit, and a blower, including an air intake opening, and an air discharge opening in fluid communication with the treated air discharge opening, wherein the air intake opening is in fluid communication with the evaporator coils.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application relates to the same subject matter as co-pending provisional patent application Ser. No. 61/799,387, filed by the same applicant on Mar. 15, 2013. This application claims the Mar. 15, 2013 filing date as to the common subject matter. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of Invention 
         [0003]    The present invention relates to heating, ventilation, and air conditioning systems. It is a device designed to ventilate, heat, and/or cool a confined space, such as the wings, fuselage, and/or tail of an aircraft during the manufacturing of said aircraft. 
         [0004]    2. Background of Invention 
         [0005]    There are numerous instances in the manufacturing industry where workers building the machine are required to perform their work in enclosed spaces with limited or no natural ventilation. For example, a worker assembling an airplane may need to perform work inside the wing of the aircraft, the tail of the aircraft, or the fuselage, all of which are enclosed areas with limited or no natural ventilation. The lack of ventilation can be hazardous to the workers in these areas. 
         [0006]    Additionally, there are numerous instances in the manufacturing industry where precise temperature control in an enclosed space is required. For example, many modern commercial airlines are constructed using composite materials. These composite materials require precise temperature control during the manufacture of the aircraft. Lack of precise temperature control can adversely affect the finished properties of the composite materials. 
         [0007]    It may also be desirable to provide both ventilation and precise temperature control at the same time. For instance, a worker working on the interior of a modern airplane wing may be applying chemicals used in the composite structure of the airplane. In such a situation it is desirable to provide both ventilation for the worker and precise temperature control so that the chemicals being used are applied appropriately to the composite construction. 
         [0008]    Therefore, there exists a need for a device capable of providing ventilation to an enclosed space that is also capable of providing precise temperature control and variation. 
         [0009]    The invention allows users to provide high flow ventilation to enclosed spaces, and to provide precise temperature control to a specific area, in a portable unit. 
       SUMMARY OF THE INVENTION 
       [0010]    In accordance with one aspect of the invention, a device for providing ventilation, heating, and/or cooling is provided. The invention may operate as a portable confined space ventilator. 
         [0011]    In accordance with another aspect of the invention, the device is portable, sitting on wheels or casters with an attached tow bar for moving the device freely. Additionally, the invention can be built with attachment points for forklifts, cranes, or other devices. 
         [0012]    The invention provides for a high powered fan and blower capable of supplying up to 9,000 cubic feet per minute of airflow with 9 inches of static pressure. The air supplied by the device is variable through the use of a control interface. An air filter may be provided and incorporated into the device to filter the output air. 
         [0013]    In accordance with another aspect of the invention, a plenum is provided that includes either four individual ducts or one large adjustable duct, allowing the operator of the device to control up to four individual air outlets from a single device. 
         [0014]    The invention may have a ‘cooling’ mode that provides for 8 or more tons of air conditioning with a temperature range of 0 to 120 degrees Fahrenheit. 
         [0015]    The invention may have a ‘heat’ mode that provides for 28 kilowatts of heat, or more. 
         [0016]    The invention is built so that it can operate under outdoor conditions, including rain, snow, sand, and extreme heat, as well as continuous “24/7” operation. The invention is capable of being used in temperatures from 0 to 120 degrees Fahrenheit. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]      FIG. 1  is a perspective view of the device. 
           [0018]      FIG. 2  is an exploded perspective view of the chassis of one embodiment of the device. 
           [0019]      FIG. 3  is a detail perspective view of one side of one embodiment of the device. 
           [0020]      FIG. 4  is a detail perspective view of the interior of one embodiment of the device. 
           [0021]      FIG. 5  is a plan view of the electronics box of one embodiment of the device. 
           [0022]      FIG. 6  is a plan view of the control panel of one embodiment of the device. 
           [0023]      FIG. 7  is a perspective view of one embodiment of the device. 
           [0024]      FIG. 8  is a detail perspective view of the interior of one embodiment of the device. 
           [0025]      FIG. 9  is an exploded perspective view of one embodiment of the device. 
           [0026]      FIG. 10  is a side view of the interior of one embodiment of the device. 
           [0027]      FIG. 11  is a detail perspective view of the interior of one embodiment of the device. 
           [0028]      FIG. 12  is a perspective view of a blower of one embodiment of the device. 
           [0029]      FIG. 13  is a detail side view of one embodiment of the device. 
           [0030]      FIG. 14  is an interior view of one embodiment of the device. 
           [0031]      FIG. 15  is a perspective view of the treated air passage of the device. 
           [0032]      FIG. 16  is a side view of the refrigeration system of one embodiment of the device. 
           [0033]      FIG. 17  is a detailed view of the refrigeration system of one embodiment of the device. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0034]    A device for providing ventilation, heating, and cooling is disclosed herein and as shown in  FIGS. 1 through 26 . 
         [0035]    The device is shown generally in  FIGS. 1 and 2  at  10 . The chassis  12  may be made portable by attaching wheels  14 , casters, skids or similar features to the bottom surface of the chassis  12 . Additionally, lifting points for a crane or other lifting device may be provided on the top of the chassis  12 . Further additionally, engagement points for a forklift may be provided on the bottom of the chassis  12 . A pull handle  16  or tow bar may also be provided on the chassis  12 . 
         [0036]    As shown in  FIGS. 3 and 4 , the device further comprises a high output blower  18  located inside the chassis  12 . The blower  18  is controlled by a motor  20  and together they are controlled by an electronics panel in an electronics box  22 , as shown in  FIGS. 2 and 5 . The blower  18  may be one such as the Model 3C106 by Dayton. The motor for the blower may be one such as the 170159.60 made by Leeson. The electronics within the electronics panel may be controlled by user inputs into a control panel  24  shown in  FIG. 6 , accessible from the outside of the chassis  10 . The control panel allows the user of the device to control the function and operation of the device. The control panel is set into the side of the chassis and contains a touch panel or other device for displaying information and accepting user input. A control panel cover may be provided to protect the control panel from outside elements. A control panel cover may provide water protection to the control panel so that the unit may be used outdoors and exposed to natural elements. 
         [0037]    The control panel allows the user to operate the device. In one embodiment of the device, four modes of operation are available: cool mode, heat mode, cure mode, and fan only mode. Additionally, manual user and maintenance modes may be provided. The control panel also gives the user access to adjust the settings of the device, check the status of the device, and to set various user-defined alarms to alert the user to various operating conditions of the device. The control panel also provides the user alerts for the drain pump and air filter of the device. These alerts inform the user of issues such as the presence of a problem with the drain pump, that the drain pans need to be emptied, or that one or more air filters need to be replaced. 
         [0038]    The chassis  12  includes an evaporator coil air intake opening  26  as shown in Figured  7  and  8 . In addition, as shown in  FIGS. 9-11 , the chassis  12  includes a treated air discharge opening  28  and a condenser coil air flow opening  30 . The device  10  further includes a condenser coil unit  32 , and an evaporator coil unit  34 . The blower  18  has an air intake opening  36  shown in  FIG. 12  and an air discharge opening  38  in fluid communication with the treated air discharge opening  28  on the chassis  12 . The air intake opening  36  of the blower  18  is in fluid communication with the evaporator coil unit  34 . Either the condenser coil unit or the evaporator coil unit, or both, may comprise a plurality of spaced apart arrays of coils. In one embodiment, the coils are made of copper tubing on an aluminum frame. 
         [0039]    When activated, the blower  18  may draw air from outside the device  10  over the evaporator coil unit  34 . The chassis  12  may be formed so that an air filter may be placed within the chassis  12  over the evaporator coil unit  34 . In one example the coils for the evaporator and/or the condenser may have a ⅜ inch diameter with a wall thickness of about 0.016 inches. Air may also be drawn through other air inflow openings formed into the chassis  12 . The air may then be passed through a heat exchanger or heating elements to change the temperature of the output air, as desired. The heat exchanger and heating elements may be switched off at the control panel  24 . The blower  18  then forces the air out of the treated air discharge opening  24 . 
         [0040]    The device  10  includes a closed loop system filled with a refrigerant as known in the art. As shown in  FIGS. 13 and 14 , the system includes a compressor  38  also known in the art. The refrigerant circulates between the compressor  38 , a condenser such as a condenser coil unit  32 , and may circulate within a heat exchanger. The compressor  38  may be located at various locations within the chassis  12 . A heat exchanger may be located between the blower  18  and a treated air discharge passage  40  (or plenum) such that air from the blower  18  is passed over the heat exchanger before being forced through the passage  40 . 
         [0041]    The condenser coil unit  32  may be a normal air conditioning condenser of a type known to those of ordinary skill in the art. Alternatively, the condenser may be comprised of pipe coils made from a material that conducts heat. Each of the coils may be bent to form a winding pattern in an array similar to that of a traditional air conditioning condenser known to those of ordinary skill in the art. Arrays may then be formed into spaced apart arrays of condenser coils. In this form air forced over the condenser coil unit  32  passes first over one pipe and then over the other pipe. The pipes are then connected to each other such that the refrigerant in the closed loop system formed by the compressor  38 , condenser, and heat exchanger, flows through a plurality of the arrays. Heat sink fins, made of conductive materials, may be attached to the conjoined arrays. This arrangement doubles the surface area of the coils forming the arrays. The condenser coil unit may be attached to one side of the chassis  12  with a mounting bracket. The condenser mounting bracket may be attached to the chassis  12  and a condenser airflow opening  26  is provided in the chassis  12  at the location of the condenser mounting bracket to allow air to be exhausted from inside the device  10 , over the condenser coil unit  32 , and out of the device  10  through the condenser coil air flow opening  30 . The chassis  12  may be formed so that an air filter may be placed within the chassis  12  over the condenser coil unit  34 . The condenser coil air flow opening  30  and the evaporator coil unit opening  26  may be covered by a louver  42  or other protective device. 
         [0042]    The device further comprises a condenser fan  44  located within the chassis  12 . The condenser fan  44  is attached to a compressor fan mount  46 . The condenser fan mount  46  may be attached to a condenser fan mounting bracket  48  on the side of the chassis  12 . The condenser fan  44  can be of varying design and type sufficient to provide adequate air flow to carry heat away from the condenser coil unit  32 , which can be easily determined by one of ordinary skill in the art. The fan mount  46  may comprise two or more fan mount arms  50 . The fan mount arms  50  may be attached on one end to the condenser mounting bracket and on the other end to the condenser fan  40 , either directly or by the use of a collar or other retaining device. The condenser fan mount  46  may be designed to reduce vibrations and noise during the operation of the device. 
         [0043]    The device may further comprise heating elements located in the same general location as the heat exchanger, between the blower  18  and the treated air discharge opening  28 . The heating elements are controlled by the electronics, which is in turn controlled by the user inputs into the control panel  24 . The heating elements may heat the air pushed from the blower  18  through the treated air discharge opening  24  in order to obtain a user&#39;s desired treated air temperature. 
         [0044]    The adjustable treated air passage  40  may comprise a plurality of discharge holes  46 . In one embodiment, the passage  40  is formed to the outer surface of the chassis  12  and is in fluid connection with the blower  18  located inside the chassis  12 . The treated air discharge opening  24  may further comprise an adjustable treated air passage  40 . For example, the passage  40  may adjust to comprise a plurality of discharge holes. In one embodiment, the passage  40  may comprise an outer element  48  and an inner element  50 . In one example, the inner element  50  may contain a single outlet hole of large diameter through which air from the blower is forced. The outer element may include a plurality of discharge holes and fit over the inner plenum element as shown in  FIG. 10 . 
         [0045]    Additional detail views of the invention are provided in  FIGS. 16 and 17 . 
         [0046]    The outer element may be attached to the inner element by an adjustment mechanism such as a hinge and latch mechanism such that the outer element may be alternatively securely attached to the inner element or may be released and swung away from the inner element exposing the inner element. 
         [0047]    The adjustable treated air passage allows the user of the device to alter the airflow output of the device. The user can close and secure the outer plenum element and attach a single, larger diameter hose to direct the air output from the device to a single location. Alternatively, the user can attach one or more independent air hoses to one or more of the outer element holes. In addition, one or more of the plurality of holes not in use by the user may be blocked using an attachable blocking plate. Thus, a user may direct the air output of the device to multiple, independent locations. This provides a substantial benefit for the user. 
         [0048]    The device may also include an automatic drainage system. The drainage system may allow condensate to exit the chassis to a condensate pan below the chassis using a pump system, either inside of or outside of the chassis. The pump system may be disabled or, alternatively, replaced with a manual drainage system. The condensate pan may also be used to store extra hoses or other parts. 
         [0049]    The device may also further comprise a condenser coil air filter frame located between the condenser coils and an outside surface of the chassis, and an evaporator coil air filter frame located between the evaporator coils and the outside surface of the chassis. 
         [0050]    In addition, a plurality of access panels may be provided on the chassis allowing access to the interior of the chassis. The panels can be placed at various locations on the exterior of the chassis and can be attached to the chassis with a variety of attachment devices. The preferred embodiment uses cam locks to secure the access panel covers to the device chassis. 
         [0051]    One or more additional openings in the sides of the chassis may provide air inflow for the device. The openings may be protected by a grille or louver  42  designed to prevent the device from ingesting foreign object debris or moisture from the surrounding environment. The grille or louver may be of varying design. The preferred embodiment is a louver that is constructed of a single piece of material that has had a series of cuts made through the metal allowing the individual fins of the louver to be bent to the desired angle. The cuts can be generally “U”-shaped with a base nearly the width of the louver and the sides of varying lengths from one inch or more. Once the individual veins of the louver are bent to the desired angle, the veins may be held in place by attachment, via welding or otherwise, to rails on either side of the louver. This construction of the louver simplifies construction and reduces the overall weight of the device. 
         [0052]    In one embodiment of the device, four modes of operation are available: cool mode, heat mode, cure mode, and fan only mode. Additionally, manual user and maintenance modes may be provided. 
         [0053]    Cool mode allows the user to set a temperature, below the ambient air temperature surrounding the device, for the air output by the device. 
         [0054]    Heat mode allows the user to set a temperature, above the ambient air temperature surrounding the device, for the air output by the device. 
         [0055]    Cure mode allows the user to input a pre-defined air flow and temperature program that will cause the device to output the required amount of air at the desired temperature for the desired amount of time to achieve a number of goals, such as controlling the air temperature around composite materials that are curing, such as carbon fiber and epoxy resin. 
         [0056]    Fan only mode allows the user to direct the device to output a certain amount of air flow without any heating or cooling of the output air. 
         [0057]    In all operation modes—cool mode, heat mode, cure mode, and fan only mode—the user can specify the desired temperature and can select automatic fan control, manual fan control, and stop. In automatic fan mode the device selects the fan speed (as a percentage of the maximum possible fan speed) at which to operate. In manual fan control mode the user selects the fan speed (as a percentage of the maximum possible fan speed) that the user desires. Stop mode stops the device from operating and places the device into standby mode.