Mounting and securing air conditioner (AC) unit and AC cage being wall mounted on railway instrument house

A mounting assembly for mounting a wall mounted air conditioner (AC) unit on a railway instrument house is provided. The mounting assembly may include a house wall including an outer metal shell layer, a middle insulation layer and an inner plywood layer. The mounting assembly may further include a threaded part coupled to the outer metal shell layer. The threaded part is configured to receive an AC mounting hardware of the wall mounted air conditioner (AC) unit to secure the wall mounted air conditioner (AC) unit to the house wall such that the threaded part enables the wall mounted air conditioner (AC) unit to be installed or removed from outside of the railway instrument house. The mounting assembly may further include an AC unit cage for protecting the wall mounted air conditioner (AC) unit. The AC unit cage has at least two side doors and a front door such that each side door of the at least two side doors is locked within the front door by corresponding bolts or a quick lock. The AC unit cage is configured for mounting on the house wall.

BACKGROUND

Aspects of the present invention generally relate to mounting and securing an air conditioner (AC) unit being wall mounted on a railway instrument house and more specifically relate to a mounting assembly including a threaded part which enables the air conditioner (AC) unit to be installed or removed from outside of the railway instrument house.

2. Description of the Related Art

Railway companies require a temperature controlled environment for their communication and signal control houses. This requirement is addressed by adding an air conditioner/heater to the traditional instrument house structure. A railway company requires a robust solution that will provide many years of reliable service and low maintenance. However, an installation and security solution is only as good as its weakest link. To provide a railway company with a viable solution all potential failures must be addressed. For example, an air conditioner (AC) unit mounting and security of an AC cage has been identified as potential failure points.

Current installation and security designs do not address providing an efficient method for applying an air conditioner (AC) unit to a railway communication and signal control house. For example, they do not address the following issues such as—maintenance issues, energy efficiency, poor space utilization, and security/vandalism concerns. Typically make shift applications have been applied which include residential wall mount units and recreational AC units which yield short term and unsatisfactory results.

Therefore, there is a need for a more efficient and secure installation and security solution for an air conditioner (AC) unit mounting and security of an AC cage both of which are wall mounted to a house wall of a railway communication and signal control house.

SUMMARY

Briefly described, aspects of the present invention relate to a mounting assembly including a threaded part which enables an air conditioner (AC) unit to be installed or removed from outside of a railway instrument house. Embodiments of the present invention provide more efficient and secure installation and security solution for an air conditioner (AC) unit mounting and security of an AC cage both of which are wall mounted on to a house wall of a railway instrument house.

In accordance with one illustrative embodiment of the present invention, a mounting assembly for mounting a wall mounted air conditioner (AC) unit on a railway instrument house is provided. The mounting assembly may include a house wall including an outer metal shell layer, a middle insulation layer and an inner plywood layer. The mounting assembly may further include a threaded part coupled to the outer metal shell layer. The threaded part is configured to receive an AC mounting hardware of the wall mounted air conditioner (AC) unit to secure the wall mounted air conditioner (AC) unit to the house wall such that the threaded part enables the wall mounted air conditioner (AC) unit to be installed or removed from outside of the railway instrument house.

In accordance with another illustrative embodiment of the present invention, a mounting assembly for mounting a wall mounted air conditioner (AC) unit on a railway instrument house is provided. The mounting assembly may include a house wall including an outer metal shell layer, a middle insulation layer and an inner plywood layer. The mounting assembly may further include an AC unit cage for protecting the wall mounted air conditioner (AC) unit. The AC unit cage has at least two side doors and a front door such that each side door of the at least two side doors is locked within the front door by corresponding bolts or a quick lock. The AC unit cage is configured for mounting on the house wall.

In accordance with another illustrative embodiment of the present invention, a method of securing and mounting a wall mounted air conditioner (AC) unit to a railway instrument house including crossing and wayside control systems is provided. The method includes providing a house wall including an outer metal shell layer, a middle insulation layer and an inner plywood layer, providing a threaded part coupled to the outer metal shell layer and providing an AC unit cage for protecting the wall mounted air conditioner (AC) unit. The threaded part is configured to receive an AC mounting hardware of the wall mounted air conditioner (AC) unit to secure the wall mounted air conditioner (AC) unit to the house wall such that the threaded part enables the wall mounted air conditioner (AC) unit to be installed or removed from outside of the railway instrument house. The AC unit cage having at least two side doors and a front door such that each side door of the at least two side doors is locked within the front door by corresponding bolts, wherein the AC unit cage configured for mounting on the house wall.

DETAILED DESCRIPTION

To facilitate an understanding of embodiments, principles, and features of the present invention, they are explained hereinafter with reference to implementation in illustrative embodiments. In particular, they are described in the context of being a mounting assembly including a threaded part for securing and mounting a wall mounted air conditioner (AC) unit to a railway instrument house. Threaded parts are pre-installed inside a metal shell of the railway instrument house so that the AC unit and an AC cage may be installed from outside of the railway instrument house. Cage mounting bolts are changed from the outside of the AC cage to inside of the AC cage. A locking mechanism of the AC cage side doors is provided inside of the AC cage instead of the outside of the AC cage. Embodiments of the present invention, however, are not limited to use in the described devices or methods.

Consistent with one embodiment of the present invention,FIG. 1represents an exploded view of a mounting assembly5including a threaded part7which enables an air conditioner (AC) unit10to be installed or removed from outside of a railway instrument house (not shown) in accordance with an exemplary embodiment of the present invention. The mounting assembly5is configured for mounting a wall mounted air conditioner (AC) unit such as the AC unit10on the railway instrument house which includes crossing and wayside control systems of a railway system. In one embodiment, the mounting assembly5comprises a house wall12including an outer metal shell layer15, a middle insulation layer17and an inner plywood layer20. The house wall12is a wall structure of the railway instrument house.

For installation of the air conditioner (AC) unit10, no holes are to be cut in the middle insulation layer17and the inner plywood layer20. The mounting assembly5eliminates the need to cut the inner plywood layer20which results in more space for mounting equipment and wiring, and also looks neater. The mounting assembly5also eliminates the need to cut the middle insulation layer17, which has good heat resistance.

The mounting assembly5further comprises the threaded part7coupled to the outer metal shell layer15. The threaded part7is configured to receive an AC mounting hardware of the air conditioner (AC) unit10to secure the air conditioner (AC) unit10to the house wall12such that the threaded part7enables the air conditioner (AC) unit10to be installed or removed from outside of the railway instrument house.

Consistent with one embodiment of the present invention, the threaded part7is a nut or an insert that eliminates a need to have a person inside the railway instrument house during installation and disassembly of the air conditioner (AC) unit10. As one example, the nut may be a rivet nut with internal threads for placing permanent threads in the outer metal shell layer15such that once in place the internal threads are ready for a screw or a bolt. The rivet nut may have a flange that extends above the outer metal shell layer15in which it is installed.

As used herein, “a threaded part” refers to a nut or an insert configured as a fastener such as a rivet nut. As used herein, “a stud” refers to a screw or a bolt that allows a screw-on component to be prefixed to a carrier component. The rivet nut and stud provides a solution for fastening resilient nut/bolt threads to a thin-walled component such as a metal wall. The rivet nut and stud can include multiple interacting parts, whether located together or apart, that together perform processes as described herein.

The techniques described herein can be particularly useful for using a rivet nut. While particular embodiments are described in terms of the rivet nut, the techniques described herein are not limited to the rivet nut but can also use other nuts such as threaded inserts.

The mounting assembly5further comprises AC cage mounting hardware22. The air conditioner (AC) unit10uses the AC cage mounting hardware22for mounting an AC cage onto it. The middle insulation layer17includes a plurality of small shallow blind holes25(1-n). Inside the railway instrument house (not shown), the mounting assembly5further comprises an AC grille30.

The Railroads use metal instrument houses to accommodate their crossing and wayside control systems. A typical house wall is constructed in layers: metal shell, plywood and insulation. The insulation provides a resistant layer which reduces heat both entering the house in summer and exiting the house in winter. The plywood is utilized for mounting equipment and to secure wiring.

In a current design of AC mounting, when a wall mounted air conditioner (AC), such as the commercial brand Bard is required, a common design practice is to cut the plywood and insulation for bolting the AC unit to the metal shell. Due to this cut, the plywood utilized in the area of the AC cannot be used for equipment mounting or wiring and the insulation value of the wall is weakened. Another drawback of this design is that the AC installation or disassembly requires two people—one person must be inside the railway instrument house to tighten or to loosen the AC mounting hardware and another person must be outside to complete the install or removal.

Consistent with one embodiment of the present invention, an AC mounting method adds threaded parts, like a rivet nut to the metal shell. This allows the AC unit10to be installed or removed from outside of the house. This eliminates the need to have a person inside the railway instrument house during the installation and disassembly processes. By using the threaded/rivet nut design there is no longer a need to cut sections out of the insulation and plywood to facilitate the mounting of the AC unit10.

Referring toFIG. 2, it illustrates a perspective view of a wall mounted air conditioner (AC) unit200from inside of a railway instrument house in accordance with an exemplary embodiment of the present invention. The wall mounted air conditioner (AC) unit200includes an AC grille205.

Turning now toFIG. 3, it illustrates a cross sectional view of a rivet nut300before compression and a cross sectional view of the rivet nut300after compression in accordance with an exemplary embodiment of the present invention. The rivet nut300is compressed onto a metal wall such as the outer metal shell layer15before the wall mounted air conditioner (AC) unit200and an AC cage are installed. The rivet nut300comes in without compression. It was compressed after it was installed on to the outer metal shell layer15.

The rivet nut300includes a deformable shank or body. Hand tools and pneumatic equipment are available for installing the rivet nut300. The rivet nut300and studs based solution is the most versatile solution for fastening. The materials used for the rivet nut300ought to offer excellent plasticity in the compression zone.

FIG. 4illustrates a schematic view of a setting process of a rivet nut400in accordance with an exemplary embodiment of the present invention. The rivet nut400and a stud405provides a solution for fastening resilient nut/bolt threads to a thin-walled component such as the outer metal shell layer15. Setting is done using an example of a spindle stroke process which includes four steps: (1). Spin on (2). Insert (3). Upset and (4). Spin off.

The rivet nut400may be made of steel, stainless steel or aluminum. For example, it may be made from standard stainless steel or A1 or A2 austenitic steel with 18% chromium and 10% nickel. The rivet nut400may have different head shapes including a flat head, a countersunk head and an extra small countersunk head. The rivet nut400may have different shank ends including an open and a closed. The rivet nut400may have different shank shapes including a round and a plain, a round and knurled, a hexagonal shank and a part hexagonal shank.

The stud405allows a screw-on component to be prefixed to a carrier component. This is particularly helpful for heavy or large parts or with concealed assembly (“hang on” assembly). The rivet nut400and the stud405enable one-side assembly solution for components with limited access just from one side. The rivet nut400and the stud405create load-bearing nut and bolt threads on thin walls where cut threads are unsuitable. The rivet nut400and the stud405provide a solution where aesthetic appearance and the ability to seal against the elements is essential.

Railroad houses are located in remote and secluded locations. An AC cage is needed to secure the AC unit10and deter vandalism. As with the current AC mounting design, the AC cage uses a bolt fastening method that requires cuts in the insulation and plywood. Since the bolts are outside of the AC cage, carriage bolts are utilized. For AC maintenance, the AC cage has a front door and two side doors. Current cage design needs six expensive railroad padlocks to secure these points. For this design, the AC cage must be disassembled to replace the AC unit10.

Consistent with one embodiment of the present invention, an AC cage for AC security includes two side doors that are locked within a front door by bolts or similar mechanism. The access to these bolts is blocked by a front door frame. This design feature eliminates the need for four railroad padlocks. A plurality of cage mounting holes is located inside the AC cage. Access to the cage mounting bolts is blocked by a side door frame. This AC cage has a larger front door, which allows a customer to replace the AC unit10without removing the AC cage.

As seen inFIG. 5, it illustrates a perspective view of an AC unit cage500in accordance with an exemplary embodiment of the present invention. The AC unit cage500comprises at least two side doors505(1-2) and a front door510such that each side door505of the at least two side doors505(1-2) is locked within the front door510by corresponding bolts or a quick lock. An access to the corresponding bolts or the quick lock is blocked by a front door frame520of the front door510. The AC unit cage500further comprises a plurality of cage mounting holes (seen inFIG. 6only) for mounting the AC unit cage500to the house wall (not shown). The plurality of cage mounting holes525(1-n) are located inside the AC unit cage500.

The mounting assembly5ofFIG. 1further comprises a plurality of cage mounting bolts (not shown). The access to the plurality of cage mounting bolts is blocked by a side door frame530of the each side door of the at least two side doors505(1-2). The AC unit cage500has the front door510sized such that it allows a customer to replace the wall mounted air conditioner (AC) unit200without removing the AC unit cage500.

As shown inFIG. 6, it illustrates a perspective view of an AC unit cage600with a front door removed in accordance with an exemplary embodiment of the present invention. The AC unit cage600comprises a plurality of cage mounting holes605(1-n) for mounting the AC unit cage600to the house wall (not shown). The AC unit cage600further comprises first and second side door lock hardware610(1-2). The AC unit cage600further comprises first and second front door padlocks615(1-2).

InFIG. 7, it illustrates an exploded view of an AC unit cage700mounted to a house wall705of a railway instrument house (not shown) in accordance with an exemplary embodiment of the present invention. The AC unit cage700comprises first and second AC cage mounting hardware710(1-2).

A mounting assembly715configured to mount a wall mounted AC unit717comprises the house wall705including an outer metal shell layer719, a middle insulation layer721and an inner plywood layer723. The middle insulation layer721comprises a plurality of small and shallow blind holes725(1-n). The outer metal shell layer719comprises a threaded part730. The treaded part730may be a rivet nut configured to receive a bolt or a stud as explained earlier.

The mounting assembly comprising the house wall705including the outer metal shell layer719, the middle insulation layer721, the inner plywood layer723and the AC unit cage700for protecting the wall mounted air conditioner (AC) unit717. The AC unit cage700having at least two side doors735(1-2) (only one side door shown) and a front door740such that each side door of the at least two side doors735(1-2) is locked within the front door740by corresponding bolts or a quick lock. The AC unit cage700is configured for mounting on the house wall705.

FIG. 8illustrates a back view of a wall mounted air conditioner (AC) unit (not seen) and an AC unit cage (not seen) from inside of a railway instrument house in accordance with an exemplary embodiment of the present invention. A house wall800is seen.

FIG. 9illustrates a cross sectional view of the wall mounted air conditioner (AC) unit and the AC unit cage at a cross section A-A inFIG. 8with detail views B, C, D in accordance with an exemplary embodiment of the present invention. InFIG. 9, a wall mounted air conditioner (AC) unit900and an AC unit cage905is shown mounted on the house wall800. The house wall800includes an outer metal shell layer912, a middle insulation layer915and an inner plywood layer917. The AC unit cage900having at least two side doors920(1-2) and a front door922such that each side door of the at least two side doors920(1-2) is locked within the front door922by corresponding bolts or a quick lock.

In particular, as seen in detail B, a side door lock bolt925is shown locked within the front door922by a front door frame930. That is, an access to the corresponding bolts or the quick lock (e.g., side door lock bolt925) is blocked by the front door frame930of the front door922. As seen in detail C, an AC cage mounting bolt935is shown locked within the side door920(2) by a side door frame940. That is, an access to the AC cage mounting bolt935is blocked by the side door frame940of the side door920(1). As seen in detail D, a rivet nut945is shown mounted on the outer metal shell layer912after compression. The rivet nut945may have a flange950that extends above the outer metal shell layer912in which it is installed.

FIG. 10illustrates a flow chart of a method1000of securing and mounting a wall mounted air conditioner (AC) unit to a railway instrument house according to an exemplary embodiment of the present invention. Reference is made to the elements and features described inFIGS. 1-9. It should be appreciated that some steps are not required to be performed in any particular order, and that some steps are optional.

The method1000, in step1005, includes providing a house wall including an outer metal shell layer, a middle insulation layer and an inner plywood layer. The method1000, in step1010, further includes providing a threaded part coupled to the outer metal shell layer. The threaded part is configured to receive an AC mounting hardware of the wall mounted air conditioner (AC) unit to secure the wall mounted air conditioner (AC) unit to the house wall such that the threaded part enables the wall mounted air conditioner (AC) unit to be installed or removed from outside of the railway instrument house.

The method1000, in step1015, further includes providing an AC unit cage for protecting the wall mounted air conditioner (AC) unit. The AC unit cage having at least two side doors and a front door such that each side door of the at least two side doors is locked within the front door by corresponding bolts. The AC unit cage is configured for mounting on the house wall. The method1000, in step1020, further includes securing and mounting a wall mounted air conditioner (AC) unit to a railway instrument house including crossing and wayside control systems.

In one embodiment, steps for installation of the rivet nut400include drilling a hole to correct diameter and threading fastener, i.e., the rivet nut400onto a tool mandrel and inserting into the hole. Then actuating the tool to properly set fastener, i.e., the rivet nut400into material such as the metal wall or the outer metal shell layer15. The fastening operation can be completed with screwing a bolt or a screw such as the stud405with the proper thread. The rivet400and the stud405combination provides a consistent firm fastening.

Additionally, any examples or illustrations given herein are not to be regarded in any way as restrictions on, limits to, or express definitions of, any term or terms with which they are utilized. Instead, these examples or illustrations are to be regarded as being described with respect to one particular embodiment and as illustrative only. Those of ordinary skill in the art will appreciate that any term or terms with which these examples or illustrations are utilized will encompass other embodiments which may or may not be given therewith or elsewhere in the specification and all such embodiments are intended to be included within the scope of that term or terms.

Respective appearances of the phrases “in one embodiment,” “in an embodiment,” or “in a specific embodiment” or similar terminology in various places throughout this specification are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, or characteristics of any particular embodiment may be combined in any suitable manner with one or more other embodiments. It is to be understood that other variations and modifications of the embodiments described and illustrated herein are possible in light of the teachings herein and are to be considered as part of the spirit and scope of the invention.