Vehicle gasket for integrated transport refrigeration unit

A refrigeration unit includes an external housing located primarily outside of a vehicle compartment of a vehicle, and an internal housing located primarily inside of the vehicle compartment. A vehicle roof of the compartment has an external layer and an internal layer spaced apart from the external layer with insulation located there between. The vehicle roof includes an opening that receives the refrigeration unit. A gasket provides a seal between the refrigeration unit and the vehicle roof. The gasket covers the exterior layer and the interior layer. The gasket is formed of multiple layers of material which are secured to one another.

BACKGROUND OF THE INVENTION

The invention relates generally to a gasket for sealing a transport refrigeration unit located within a vehicle. More particularly, the invention relates to a gasket for sealing an opening in a vehicle that receives the transport refrigeration unit.

Conventional transport refrigeration units provide cooling inside a vehicle compartment. The conventional transport refrigeration units are typically located on a vehicle roof within a refrigeration unit housing. The transport refrigeration unit cools air that is pumped into the vehicle compartment to provide cooling. The components produce heat and vent within the refrigeration unit housing. The vehicle roof acts as an insulator to protect the vehicle interior from the heat produced by the refrigeration unit. Locating the refrigeration unit housing on the vehicle roof is unsightly.

It would be desirable to locate the refrigeration unit within the vehicle compartment to hide the refrigeration unit components from external view. However, external air must be able to reach the refrigeration unit components within the vehicle to provide cooling. If the refrigeration unit is located within the vehicle, an opening must be provided in the vehicle to allow the refrigeration unit to be located within the vehicle compartment and provide access to the external air for cooling. However, the opening in the vehicle can allow air and water to enter the vehicle and the refrigeration unit.

Therefore, an arrangement for sealing an opening in a vehicle that receives a transport refrigeration unit while providing external air to the refrigeration unit components is needed.

SUMMARY OF THE INVENTION

In the present invention, a vehicle roof supports a refrigeration unit. The refrigeration unit includes an external housing located primarily outside of a vehicle compartment and an internal housing located primarily inside of the vehicle compartment. The internal housing is located within an opening in the vehicle roof. The vehicle roof has an external layer and an internal layer spaced apart from the external layer. Insulation is placed between the external layer and the internal layer to insulate the vehicle compartment from external air.

A gasket is located between the refrigeration unit and the vehicle roof to seal the opening. The gasket extends from a top side of the vehicle roof to the bottom side of the vehicle roof to cover the exterior layer and the interior layer. The gasket is formed of multiple layers of material with are secured to one another. An aluminum layer is secured to the butyl layer, and a butyl layer is located adjacent to the vehicle roof. The butyl layer acts as an adhesive to attach the aluminum to the vehicle roof. The aluminum layer is adjacent to the internal housing when the refrigeration unit is assembled into the opening. The aluminum layer prevents ingress of water, air, and other contaminants into the vehicle roof through the opening.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1illustrates a vapor compression system10, such as a refrigeration system, including a compressor12that compresses a fluid, such as refrigerant. From the compressor12, the refrigerant is delivered downstream to a heat exchanger, such as a condenser14. In the condenser14, the refrigerant rejects heat to an external fluid medium. In the embodiment shown, the external fluid medium is air. From the condenser14, the refrigerant travels to an expansion device16and is expanded to a low pressure. The refrigerant accepts heat from another fluid medium, such as air, in an evaporator18and then flows to the compressor12, completing the cycle.

FIG. 2shows a perspective view of a refrigeration unit20of the present invention including the vapor compression system10. A vehicle roof22supports the refrigeration unit20. The refrigeration unit20includes an external housing24and an internal housing26. The external housing24is located primarily outside a vehicle compartment21and above the vehicle roof22. The internal housing26is located primarily inside of the vehicle compartment21and under the vehicle roof22, as shown. External air enters the external housing24through a first opening28located between the vehicle roof22and the external housing24. As shown, the refrigeration unit20can include multiple first openings28to increase the airflow into the refrigeration unit20. The air passes over the components of the refrigeration unit20, such as the condenser14and the compressor12, and is heated. The now heated air exits through a second opening30in the external housing24. A cover32may be located at the second opening30to reduce the amount of water and other external contaminants that may enter the refrigeration unit20through the second opening30. Additionally, the external housing24also assists in preventing water and other external contaminants from entering the refrigeration unit20.

By discharging air outside of the vehicle compartment21to remove heat from the components of the vapor compression system10, the refrigeration unit20can be located within the vehicle compartment21and under the vehicle roof22without heating the vehicle compartment21, and is therefore less unsightly. The refrigeration unit20is hidden from external view, any heat generated by the components is removed through the second opening30without affecting the temperature of the air in the vehicle compartment21.

FIG. 3shows the vehicle roof22including an opening34for receiving the internal housing26of the refrigeration unit20. The vehicle roof22includes an external layer36and an internal layer38. The internal layer38is spaced apart from the external layer36. Insulation40is located between the external layer36and the internal layer38. The external layer36, the internal layer38and the insulation40insulate the vehicle compartment21from the external air and the outside air. Thus, when the refrigeration unit20is operating, the vehicle compartment21remains cool. However, the opening34in the vehicle roof22can allow air, water and other external contaminants to reach the insulation40, the interior layer38and the vehicle compartment21. The air, the water and other contaminants can cause leakage or rusting. Thus, the opening34must be sealed.

FIG. 4shows the opening34in the vehicle roof22sealed by a vehicle gasket42. The gasket42extends from a top edge23of the vehicle roof22to the bottom edge25of the interior layer38of the vehicle roof22covering and sealing both the exterior layer36and the interior layer38. The width of the gasket42can be modified for each vehicle as the space between the exterior layer36and the interior layer38varies, changing the overall distance from the top edge of the vehicle roof22to the bottom edge of the vehicle roof22.

FIG. 5shows a cross-section of the vehicle roof21, the gasket42and the internal housing26. The aluminum layer46is formed of multiple layers of material with are secured to one another. The aluminum layer46is secured to the butyl layer44and the butyl layer44is located adjacent to the vehicle roof22. The butyl layer44acts as an adhesive to attach the gasket42to the vehicle roof22and to assist in sealing against water and air ingress. The aluminum layer46is adjacent to the internal housing26when the refrigeration unit20is assembled into the opening34. The aluminum layer46prevents ingress of water, air, and other contaminants into the vehicle roof22through the opening34to prevent corrosion of the vehicle roof22. The aluminum layer46is preferably thin enough to allow for some deformation and shaping of the gasket42. The aluminum layer46and the internal housing26have an interference fit to aid in sealing the vehicle roof22and the vehicle compartment21. The butyl layer44acts as an elastomeric and a gasket to assist in sealing the opening34.