Abstract:
A PTAC louver assembly for glazing in a window wall which is field adjustable for fastening to a PTAC sleeves provided by different manufacturers. A unique system includes inwardly directed flanges which form a box within a box when mated to the PTAC sleeve. Sealant between the flanges and the PTAC sleeve provide a substantially water tight assembly. By sealing between the sleeve and the lower sill flange, the need to seal the sleeve face and to align weep holes in the PTAC sleeve is no longer necessary. Blank-off panels are filled with high temperature insulation which allows the louver system to be painted and baked after assembly. A unique louver blade assembly uses sliding retention bars with aligned notches to receive and capture louver blades using a clamping force.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims benefit of U.S. Patent Application Ser. No. 61/268,418, filed Jun. 12, 2009, the disclosure of which is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present disclosure is directed to a louver system for use with packaged terminal air conditioner (PTAC) system, sometimes referred to as single packaged air conditioning systems. More specifically, the PTAC louver system is mountable into a commercial window wall for an aesthetically pleasing installation, eliminates known problems with water infiltration and is field adjustable. 
       BACKGROUND 
       [0003]    Packaged terminal air conditioning systems are well known and widely used in commercial buildings. They are particularly identified with transient housing such as hotels and motels and are frequently used in assisted living facilities. PTAC systems are self-contained air conditioning and heat units designed to heat and cool a limited space such as a hotel room or very small apartment. PTAC systems are installed through the exterior wall of the building such that the air inlet portion of the system generally projects outward beyond the outer wall of the building and the air venting portion of the system is positioned inward through the interior wall of the building. Generally, the heating and cooling mechanism is housed within a metal sleeve. 
         [0004]    PTAC systems are most commonly found in buildings that are three stories or less. Typically, taller buildings will have central HVAC systems. PTAC systems have several highly desirable attributes. They are generally less expensive than HVAC systems, are generally simple to install, repair and replace and easily allow the occupants of each individual room to independently control their own temperature setting. 
         [0005]    There are, however, several drawbacks to PTAC systems. Often, architects, designers and building owners find PTAC systems to be unsightly with individual units projecting from each room of the building. Further, where the air inlet portion of the PTAC system is recessed in the building so that the louver is flushly mounted to the building façade these systems are prone to water infiltration and failure to drain accumulated water and condensation. This is particularly true with existing PTAC systems mounted in commercial window walls. An installer must achieve a perfect seal between the louver and the outside edge of the PTAC sleeve and take care not to inadvertently plug weep holes provided through the PTAC sleeve. Further, the installer typically must tilt the sleeve outward to facilitate drainage and eliminate water entrapment. Water infiltration around the PTAC sleeve will generally degrade the building wall at an accelerated rate. Moreover, water that can accumulate in the PTAC sleeve may be diverted to the interior of the room and it is not uncommon for drywall, flooring and other building materials to become damaged. 
         [0006]    Another problem with PTAC systems is that each manufacturer generally utilizes different mounting configurations on the PTAC sleeve and it is impossible to select and mount existing louvers in a window wall until the manufacturer for the PTAC sleeve is known. PTAC systems are commercially manufactured in uniform sizes. For example, one common configuration is a unit 42 inches wide by 16 inches tall. The exterior louvers, as manufactured by different companies, however, are provided with different installation bolt patterns or attachment features, have diffuser grills in specific fixed locations, and pre-formed sill notches to align with weeps. Accordingly, designers and builders have to specify which PTAC manufacturer will be used very early on in the building design and construction phase to ensure that the louver preparation will match the PTAC sleeve. This may not be a problem where PTAC installation includes positioning the PTAC through the building wall and fastening an exterior louver directly to the sleeve and independent of glass or glazing. The building trend, however, is to integrate the exterior PTAC louver into the exterior window wall so that the louver is substantially flushly mounted thereto. This installation technique is intended to increase the aesthetic desirability of PTAC use by integrating the louver flushly with the building exterior and eliminating unsightly detached louvers. With this mounting method for existing louvers, it is very difficult to achieve the necessary face seal between the louver and the sleeve. The instant invention eliminates the need for this face seal with a inner box formed by louver frame members into which the PTAC sleeve is positioned. A seal can easily be formed between the frame members and the sleeve. 
         [0007]    Currently, for PTAC system installation into a building which includes a window wall, it is imperative that the building designer specify very early on in the design and construction process the manufacturer of the PTAC systems to be used. This ensures that the correct louver preparation can be fabricated so that the louver mounting mechanisms will mate to the PTAC sleeve of the selected PTAC manufacturer. 
         [0008]    To date, there are no known PTAC louvers being manufactured which are readily adjustable for mounting to a variety of PTAC sleeves available from different PTAC manufacturers. Moreover, there appears to be virtually no effort to limit or control water intrusion through existing exterior PTAC louvers other than to recommend the liberal use of sealants between the louver and the building facade or the louver and the PTAC sleeve. 
         [0009]    Turning now to the issue of PTAC louver construction, there have historically been several manufacturing difficulties. The first difficulty is that most available PTAC louvers can only be mounted to a PTAC sleeve manufactured by a known PTAC manufacturer. Heretofore, there has been no effort to provide field adjustment of these systems. Next, during the manufacturing process it is extremely difficult to properly orient and mount the louver blades. The accepted method within the industry is to provide parallel louver blade retention bars. Each bar is provided with a series of horizontal slots in serial alignment along the vertical axis of bar. The retention bars are substantially U-shaped with the retention slots formed through the lowermost portion of the U so that they project generally upward into each of the legs of the U-shaped bar. A plurality of louver blades are positioned within the retention bar slots. A roller or similar device is then used to mechanically crimp that portion of each louver blade that projects inwardly into the U-shaped retention bars. This method, while seemingly simple, provides substantial complexities. 
         [0010]    If any individual louver blade is misaligned or becomes misaligned or is damaged during the crimping process, it is generally necessary to discard the entire louver assembly and start over. Further, if a plurality of louver blades are improperly aligned either horizontally or vertically during the crimping process, the louver assembly will have an improper installation and a poor aesthetic appeal. 
         [0011]    It is highly desirable to provide a louver blade mounting assembly which allows the blades to be firmly secured within the louver assembly during the manufacturing process, but in the event of an improper alignment, or other manufacturing problem a system that allows individual blades to be repositioned or easily removed and replaced. The instant invention provides for such a process. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0012]      FIG. 1  is a cross-sectional view of prior art showing a traditional mounted PTAC sleeve with a unitary architectural grill. 
           [0013]      FIG. 2  is a cross-sectional view of prior art showing a flush mounted PTAC sleeve with louver within a window wall. 
           [0014]      FIG. 3  is a plan view of the exterior of the inventive PTAC louver assembly. 
           [0015]      FIG. 4  is a vertical cross-sectional view taken along line  4 - 4  shown in  FIG. 3 . 
           [0016]      FIG. 5  is a horizontal cross-sectional view taken along line  5 - 5  shown in  FIG. 3 . 
           [0017]      FIG. 6  is a detailed cross-sectional view of the header assembly within  6 - 6  of  FIG. 4 . 
           [0018]      FIG. 7  is a detailed cross-sectional view of the sill assembly within  7 - 7  of  FIG. 4 . 
           [0019]      FIG. 8  is a detailed cross-sectional view of the jamb assembly within  8 - 8  of  FIG. 5 . 
           [0020]      FIG. 9  is a plan view of the interior of the inventive PTAC louver assembly showing the orientation of retention bars and associated air diffusers. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    Referring now generally to  FIGS. 1 and 2 , traditional mounting methods for PTAC systems within a wall of a building are shown. A PTAC system  102  provides heating and air conditioning to a room  104  and is somewhat similar to a traditional window mounted air conditioning unit in that it is self-contained. The PTAC system  102  generally includes a sleeve  106  which is a rectangular metal box positioned through and mounted in an exterior wall  108  of the building. Air is drawn from the exterior of the building  110  through the PTAC system  102  where it is either heated or cooled and expelled into the interior  104  of the building. The instant invention is drawn to the louver or exterior grill  112  which covers the outermost or exterior portion of the PTAC system  102 . The louver  112  allows air to be drawn into the PTAC system while limiting rain and other elements from entering the PTAC sleeve  106 . The louver  112  also provides a mechanism to quickly drain water and condensation from the PTAC sleeve  106 . Moreover, the louver  112  provides an aesthetic appearance to the PTAC installation. 
         [0022]      FIG. 1  shows a traditional PTAC installation where the PTAC sleeve  106  is positioned through the building wall  108  with a substantial portion of the system exterior to the building. A very simply unitary grill  112  is used to cover the outside of the PTAC system.  FIG. 2  shows an alternative installation that is often preferred by architects and designers. The installation shown in  FIG. 2  brings the entire visible portion the PTAC sleeve  106  interior to the building such that the grill mounted on the exterior of the building is substantially flush with the exterior wall  108  of the building. 
         [0023]    Because many designers and architects do not like the appearance of grills fastened to the exterior walls of buildings, and because of installation limitations and water leaking issues, it is greatly preferred to integrate the grill or louver system within a window wall as shown in  FIG. 3 . It is to be understood that the PTAC louver described and claimed herein is intended for use with a window wall and will typically be glazed into the window wall by the manufacturer. This design method blends the louver system in with the remainder of the window, and when the louver is finished to match or complement the remainder of the building exterior, the presence of PTAC systems in the building may go unnoticed based on the exterior or outside appearance of the building. 
         [0024]    Now referring generally to  FIGS. 3 through 9 , the PTAC louver assembly  120  of the instant invention is shown. The PTAC louver assembly  120  of the instant invention includes innovative louver blade retention bars  122 . As best shown in  FIG. 5 , multiple louver retention bars  122  are utilized in each PTAC louver  120  to facilitate proper blade retention and orientation of the individual louver blades  124 . The inventive louver blade retention bars  122  further comprise an inner retention bar or backer  126  inverted and nested within an outer retention bar or strut  128 . Each backer  126  and strut  128  may be substantially U-shaped although it is preferred that the backer  126  is T-shaped. The backer  126  is necessarily smaller in dimension than the outer retention bar  128 . Both the backer  126  and the strut  128  are provided with a plurality of horizontal blade retention slots  130  aligned vertically along the length of the bar. On the strut  128 , the slots  130  are formed through the “U” of the base  132  and project generally into the legs or stems  134  of the U-shaped bar. On the backer  126 , the slots  130  are formed through the opposed legs  134  of the U-shaped bar toward the base  132  of the “U”. Where the preferred “T” shaped backer  126  is used, the stem or leg  134  of that bar is nested into the lower portion  132  of the outer U-shaped strut  128 . In that configuration, the slots  130  in the strut  128  are serially aligned with slots  130  formed along the leg of the T-shaped backer  126 . 
         [0025]    During the manufacturing process, the backer  126  is nested inside the strut  128  and the retention slots  130  of the backer  126  and strut  128  are aligned. A PTAC louver blade  124  is inserted into each slot  130  so that it projects inwardly through the retention slot of the outer strut  128  and into the slot  130  of the backer  126 . It is understood that multiple retention bars  122  are used along the length of the PTAC louver blades  126 . At least two are necessary, and three or more are preferred, to allow for the necessary orientation, retention and stability of the PTAC louver blades  124 . 
         [0026]    When the individual PTAC louver blades  124  have been inserted in the retention slots  130  of both the strut  128  and aligned backer  126  and each blade  124  has been properly oriented such that each louver blade  124  is in substantial alignment in all directions, the backer  126  is moved linearly within the strut  128  by force. This movement causes a lateral offset of the backer slots  130  respective the strut slots  130  which results in each individual louver blade  124  becoming mechanically captured by the clamping movement of the backer slots with respect to the strut slots. 
         [0027]    Because the dimensions of each louver blade  124  and the retention bar slots  130  are generally quite small, a very small movement of the backer  126  within the strut  128  is necessary to capture and retain the louver blades  124 . Further, each louver blade  124  includes a nub  136  formed along the inner length which is captured within a slot  130  of the retention bar. This nub  136  substantially increases the retention force created when the backer  126  and strut  128  are offset and clamped during the fastening process. If any of the louver blades  124  become misaligned or damaged during the process, the backer  126  is simply returned to its original position so that each louver blade  124  can be removed or repositioned. Once the louver blades  124  have been properly captured and are in the correct orientation, the backer  126  is retained in the desired position with set screws  125  through the louver frame extrusion. This fastener can also be used to mechanically move the backer  126  within the strut  128  to exert the desired clamping force on each louver blade. 
         [0028]    For adjustability, the innovative PTAC louver  120  includes several novel features. It is understood that the inventive PTAC louver is specifically configured for use in a window wall  138  and is not a louver that is simply mounted or fastened to the exterior portion of a PTAC sleeve  106 . As such, the PTAC louver can be manufactured for integration into a window wall  138  by a window manufacturer. If the specific PTAC manufacturer is unknown at the time of window construction, it is impracticable to correctly orient the mounting features onto the PTAC louver to mate with a specific sleeve of a manufacturer. The most common method for mounting the exterior louver or grill  112  onto the PTAC sleeve is to provide bolt holes through an inwardly directed exterior flange portion of the sleeve itself, as shown in  FIGS. 5 and 8 . The louver  112  is then aligned to the PTAC sleeve  106  and fastened with bolts passing through the bolt holes formed in the sleeve into a threaded bolt receiver or nut pre-positioned on the inner surface of the louver, preferably provided on the louver retention bars. 
         [0029]    In the instant invention, the mounting process provides substantial adjustability. No permanently placed bolt receivers are provided on the interior surface of the louver  112 . Rather, races  142  are provided on the inner-facing surface of each at least two of the backers  126 . These races  142  are formed on backers  126  having a T-shape and the races are generally oriented inward toward the PTAC sleeve as shown in  FIG. 8 . When a threaded nut  146 , or similar fastening device, is placed within the race  142 , it can be moved up or down along the length of the race  142 . When the louver  112  is to be mounted to the PTAC sleeve  106 , threaded studs  148  are provided and positioned within the nut  146  positioned in the race  142  such that the threaded portion of the stud  148  is inwardly projecting. The louver retention bars  122  are moved horizontally along the louver blades until the associated threaded stud  148  is generally horizontally aligned with the holes  140 . The nuts  146  and associated stud  148  are then moved vertically within the race so that they align with the mounting holes  140  which are factory provided in the PTAC sleeve  106 . The threaded studs  148  are passed through these holes  140  and fastened in place with conventional fasteners such as nuts, wing nuts or the like opposing the nut  146 . It is understood and appreciated that a variety of different fasteners can be used to connect the louver to the PTAC sleeve without departing from the invention. 
         [0030]    As shown in  FIG. 9 , PTAC louvers are often provided with air diffusers  160  which prevent or substantially limit the convection of air within the PTAC sleeve  106 . Again, the manufacturer of the PTAC system must be known to properly position air diffusers  160  on a louver. The inventive louver, however, provides diffusers  160  on the interior portion  144  of the louver assembly  112  which can be moved laterally along the length of the louver  112  to accommodate the dimensions provided by different PTAC manufacturers. The diffusers  160  are mounted on the interior portion of a louver blade retention bar  122 . It is preferred for field adjustability that the diffusers  160  are mounted to separate blade retention bars  122  from those bearing fasteners  148  used to connect the louver  112  to the PTAC sleeve  106  but it is understood that the diffusers  169  can be mounted on common bars  122  with the fasteners  148 . Where separate blade retention bars  122  from are used to mount the air diffusers  160 , it is preferred to eliminate the backer  126  and use only the strut  128  as this allows easy horizontal movement of the bar  122  along the louver blades  124 . Where a complete blade retention bar  122  is used for mounting the diffuser  160 , horizontal movement is accomplished by releasing the set screws  125  which hold the retention bars  122  in place on the louver blades  124 . The bar  122  is then moved horizontally along the length of the PTAC louver to the desired position and the set screws  125  are tightened to retain the retention bar  122  and associated air diffuser  160  in the desired horizontal position. Vertical movement of the diffuser  160  is accomplished by vertical positioning of fasteners used to mount the diffuser onto the bar  122 . 
         [0031]    When PTAC louvers  112  are glazed in window walls  138 , the dimensions for the louver specified by the architect or designer are often different from the dimensions of the PTAC louver  112  necessary for attachment to the PTAC sleeve  106 . Generally, the dimensions of the louver  112  will be larger than the dimensions of the PTAC sleeve  106 . Accordingly, blank-off panels  170  are often provided on the inner surface  144  of the louver  112  as best shown in  FIGS. 5 and 9 . These blank-off panels  170  close any gaps existing between the PTAC sleeve  106  and the outer dimensions of the PTAC louver  112  and prevent air and water from passing through the louvers  112  around the periphery of the PTAC sleeve  106 . The blank-off panels  170  allow PTAC louver  112  to be manufactured in sizes much wider and taller than PTAC sleeve  106  assemblies for aesthetic purposes. Generally, the blank-off panels  170  are filled with insulation. The instant device incorporates a high temperature insulation  172  in the blank-off panels  170  so that the insulation  172  can withstand baking temperatures of up to 400 degrees Fahrenheit during the louver painting process. In the past, it has been necessary to paint different parts of the PTAC louver assembly, bake on the paint at high temperatures and then assemble the louver because of the propensity to melt insulation in the blank-off panels. The use of high temperature resistant insulation such as polyisocyanurate foam core allow the PTAC louver of the instant invention to be fully assembled prior to painting which substantially decreases labor and the overall cost of manufacturing. 
         [0032]    Turning now to the specific manufacture of the inventive device, a substantially rectangular frame  114  for the PTAC louver  112  is formed. This frame member  114  will generally be extruded aluminum. The frame extrusion will have a header  180 , a sill  182  and opposed sides or jambs  184  which, when joined together, form the substantially rectangular frame  114 . The frame extrusion  114  for the headers  180 , sill  182  and jambs  184  will include a generally U-shaped seat  186  which is configured for mounting in place of glazing a section of glass into the frame of a window wall  138 . Generally the PTAC louvers  112  of the instant invention will be manufactured and then placed into a window wall  138  by the window manufacturer. 
         [0033]    As best shown in  FIG. 6 , the header  180  of the louver frame  114  includes an exteriorly positioned flange  188  which depends downward as shown. This downwardly projecting flange  188  directs protects the louver blades  124 . The header also includes an inwardly projecting flange  190  which is intended to overlie the PTAC sleeve  106  as shown. The inner flange  190  allows a seal  192  to be formed between the PTAC sleeve  106  and the header  180 , and further acts to stabilize the sleeve  106  within the wall assembly  138 . 
         [0034]    Referring now to  FIG. 7 , the sill  182  of the PTAC louver frame  114  is shown. An inwardly projecting flange  194  underlies the lowermost portion of the PTAC sleeve  106 . A shim  196  is provided between the inner frame flange  194  and the PTAC sleeve  106  as shown to create a workable joint thickness. Sealant  198  must be field installed in the joint between the PTAC sleeve  106  and the flange  194  to eliminate water intrusion. During installation it is the PTAC manufacturer&#39;s requirement that the PTAC sleeve  106  have a modest slope oriented outward  110  to facilitate water drainage from the sleeve  106  into the louver assembly  112 . An exteriorly oriented flange  200  includes an upward projecting bar  202 . A weep  204  is formed in the bar  202  to allow water passing into the louver  112  to drain exterior the louver assembly. Notches  204  provided intermittently along the width of the bar  202  will properly serve as a weep for the louver assembly. The use of these notches  204  is advantageous in that alignment of the louver weep with the weeps provided in the PTAC sleeve is not necessary. Because the inner flange  194  underlies the PTAC sleeve  106  and a sealant  198  is provided between the sleeve and the flange, any water passing from the weep formed in the PTAC sleeve drains into the louver assembly and will migrate to the weep notch  204  formed in the exterior bar  202  of the louver assembly  112 . Accordingly, the weep of the PTAC sleeve does not have to be aligned with the weep formed in the PTAC louver. 
         [0035]    Now turning to  FIG. 8 , the louver assembly is viewed from the top such that each side or jamb  184  of the frame  114  is in view. The frame sides  184  include U-shaped rails  186  for glazing into a window  138 . The side frame members  184  also include outwardly projecting retention members  206  which overlie the ends of the louver blades  124 . This retention member  206  provides aesthetic appearance to the louver in that the blade ends are not viewable from the exterior. Moreover, they protect the blade ends from damage. 
         [0036]    As shown in  FIGS. 5 and 8 , fasteners  148  are provided for attaching the PTAC louver  112  directly to the PTAC sleeve  106 . The fasteners  148  are mounted into races  142  which are formed on the innermost surface of the backer  126 . A fastener, such as a hex nut  146  is positioned within each race  142 . The nut  146  slides within the race  142  into the necessary vertical position to match mounting holes provided through the PTAC sleeve  106  by the manufacturer. Threaded studs  148  or other proper fasteners are then used to secure the PTAC sleeve  106  to the provided louver. A hex nut or similar fastener secures the threaded stud  148  through the sleeve. As needed, the retention bars  122  can be moved horizontally to further align the fasteners  148  with the holes in the PTAC sleeve  106 . 
         [0037]    A blank-off panel  170  is shown in  FIGS. 5 and 8 . It is understood that a second blank-off panel, while not shown, would likely be provided on the other side of the PTAC sleeve for uniformity. One or more blank-off panels can be used. It is further understood that the blank-off panel dimensions can range widely depending on the overall dimensions of the PTAC louver designated by the architect or designer. Each panel is provided with high temperature insulation  172 . Custom extruded aluminum meeting rails  210  are preferably used between the blank-off panels  170 , and the sides of the PTAC sleeve  116 , for a further customizable fit. The meeting rails  210  and the inwardly directed flanges  190 ,  194  provided on the header and sill cooperate to form a box-shaped receiver into which the PTAC sleeve is positioned and mounted. This forms a box within a box connection between the PTAC louver  112  and the PTAC sleeve  106 . As shown, it is preferred that sealant  198  is applied between the meeting rail of the louver and the PTAC sleeve. This box within a box configuration results in a desirable fit between the sleeve  106  and the louver  112  and facilitates a uniform seal entirely around the sleeve. 
         [0038]    It should be understood that this invention is not limited to the embodiments disclosed herein but is capable of numerous rearrangements, modifications and substitutions without departing from the spirit of the inventions which is only limited by the appended claims.