Weather guard apparatus for air conditioning units

A system for protecting air-conditioning units from damage caused by hail and other inclement weather conditions is described. The system includes one or more protective panels, each having a frame and a protective screen. The panels are attached to the housing of an air-conditioning unit using a variety of brackets and clamps. The system protects air-conditioning units without significantly restricting the air flow around the units and additionally shades the units to enhance their performance by lowering their temperature.

BACKGROUND

The present invention relates generally to protective housing for air-conditioning units and heat pumps, and in particular to a protective unit capable of protecting exposed, including rooftop, air-conditioning units from hail and other inclement weather damage while being easy to assemble and disassemble.

Outdoor air-conditioning units typically include a compressor, a condenser, a grill, various piping and valves, and a fan all contained within a metal housing. The purpose of an air-conditioning unit is to transfer the heat from a building or structure to refrigerant in the air-condition system piping, and then transmit this heat to the ambient environment outside of the building or structure.

In commercial applications, the units are commonly located on the rooftop of a building. As a result, the air-conditioning unit may be exposed to direct sunlight as well as hail and other inclement weather conditions. Hail poses a particular hazard to air-conditioning units because hail striking the grill of a unit can deform the thin metallic fins that compose the grill. This results in lowered air-conditioning efficiency of the unit. To correct a grill damaged by hail, a repairman will frequently attempt to straighten the fins that were bent or otherwise deformed by the hail.

Rooftop exposure to sunlight can also increase the temperature of an air-conditioning unit and its internal components. This can reduce the heat-transfer rate from the air-conditioning unit, and significantly impact the air-conditioning unit's efficiency. Exposure to sunlight can also lead to increased head pressures within the unit potentially resulting in the unit shutting it down or failing.

Periodically, air-conditioning units must be serviced. This often requires access to the grills of the unit and the upper surface of the unit, typically where the compressor fan discharges hot air.

Protective hoods for room-type air-conditioning units are known in the art. U.S. Pat. Nos. 2,705,990; 2,892,242; 2,901,989; and 2,941,380 are examples of apparatus and systems for protecting air-conditioning units installed in windows. However, none of the inventions of these patents provide an apparatus that can collectively guard rooftop air-conditioning units against hail, provide protection from sunlight, and can be quickly and easily assembled and disassembled. For example, U.S. Pat. No. 2,705,990 discloses a “ventilated tarpaulin” that fits snugly over the exposed areas of a window-sill installed air conditioner. This apparatus is insufficient to guard against hail because it does not provide a rigid barrier around the grills of the air conditioning unit to deflect hail.

Solar shades or sun shrouds known in the art, such as those disclosed in U.S. Pat. Nos. 4,768,350 and 6,595,017 and U.S. patent application Ser. Nos. 10/393,619 (U.S. 2003/0177703 A1) and 10/064,090 (U.S. 2003/0226369 A1), also do not address these needs because the solar shades are either not constructed of sufficiently sturdy material, are not sufficiently securely attached to the air-conditioning units to withstand hail, or are not easily assembled and dissembled.

A need exists, therefore, for apparatus capable of guarding exposed air-conditioning units from hail and other inclement weather conditions that is capable of being quickly and easily assembled and disassembled to facilitate servicing of the units. A need also exists for apparatus that can provide solar shade to rooftop air-conditioning units that also can resist hail strike and other inclement weather conditions.

All references cited herein are incorporated by reference to the maximum extent allowable by law. To the extent a reference may not be fully incorporated herein, it is incorporated by reference for background purposes and indicative of the knowledge of one of ordinary skill in the art.

SUMMARY

The present invention is directed to a system and apparatus that satisfies these needs. The apparatus of the present invention comprises one or more protective panels220. Each protective panel220is made of a frame222and a protective screen224. The screen is preferably made of non-metallic breathable material. One or more protective panels220are securely attached to the upper portion of the housing102of the air-conditioning unit100. The lower portion of the protective panels220are supported by one or more support rods230, which are securely attached to the lower portion of the housing102of the air-conditioning unit100.

In another embodiment of the present invention, the upper portion of the protective panel220is rotatably secured to the upper housing102of the air-conditioning unit100such that the angle of the panel220relative to the vertical surface of the housing102may be adjusted before the panel220is securely fastened. This allows a user to optimize the degree of protection from hail based on the weather conditions in the particular geographic area in which the weather guard200is installed.

In another embodiment of the invention, the lower portion of the frames222of the protective panels220supported by support rods230are secured by clamps244, which can be easily removed. This allows a user to quickly and easily lower the protective panel220to facilitate repair or servicing of the air-conditioning unit100.

In another embodiment of the present invention, the screen224of the protective panel220is comprised of solar screen material capable of deflecting the sun's rays, thereby shading and lowering the temperature of the air-conditioning unit100.

In another embodiment of the present invention, the screen224of the protective panel222is pillow shaped and accepts the frame222of the protective panel220inside the cavity of the screen224. The screen224also has a flap that facilitates installing and removing the frame222.

In another embodiment of the present invention, a triangular protective panel260is included and installed between two adjacent protective panels220to further enhance protection from hail.

Other objects, features, and advantages of the present invention will become apparent with reference to the drawings and detailed description that follow.

DESCRIPTION

FIG. 1illustrates a typical rooftop air-conditioning unit100having housing102, condenser fan104, grill106, and fins108. The weather guard200includes one or more protective panels220. In the preferred embodiment, every side of the air-conditioning unit100having a condenser grill106is protected by the weather guard200. For example, inFIG. 2, only two sides of air-conditioning unit100have compressor grills106. Therefore, two protective panels220and an optional triangular protective panel260are installed on the sides of the air-conditioning unit100having condenser grills106. The triangular protective panel106is not required by the invention, but its inclusion enhances performance by providing additional protection from hail, which otherwise would not be stopped by the rectangular protective panels220.

FIGS. 4 through 6illustrate the protective panel220and its components. Protective panel220is composed of a frame222and a protective screen224. Although copper is preferred, the frame222may be constructed of cvc, piping, wood, steel, aluminum, plastic, or some other rigid material. The material must be of sufficient rigidity to withstand hail striking the unit without it breaking. It should additionally be appreciated that the frame222may formed of any suitable shape and size. In the preferred embodiment shown inFIG. 2, the frame222is rectangular or square in shape, depending on the shape of the air-conditioning unit100sides. The frame222is preferably sized so that substantially one side of the air-conditioning unit100is shielded by the protective panel220.

Protective screen224is made of nylon mesh and the like breathable material. Preferably, the material is not made of metal because metal will retain heat from the sun causing the air-conditioning unit's temperature and possibly its head pressure to increase, thereby reducing its performance. In the preferred embodiment, the material is made of at least 90-degree highly solar deflective shading mesh or includes a layer of solar material attached to nylon mesh. This type of material is disclosed in U.S. Pat. No. 6,595,017 (column 3). However, the material selected must be sufficient sturdy to deflect hail striking the panel.

However, unlike the solar shade disclosed in U.S. Pat. No. 6,595,017, the protective screen224cannot be attached to the frame through the use of double-sided tape, epoxy, or rubber strips. Rather, it must be fastened sufficiently secure to resist hail striking the protective screen224. In one embodiment, the protective panel220is constructed by placing the frame222on top of the protective screen224. The protective screen224should be larger than the frame222such that material of the protective screen224is folded over the frame222forming flaps226as shown inFIG. 4in phantom lines. The flaps226are then secured, preferably by double stitching, to the material of the protective screen224on the opposite side of the frame222.

In the preferred embodiment shown inFIG. 6, the protective screen224is made of a shape substantially similar to a pillowcase and has one flap228near the opening of the screen. The protective panel220is constructed by inserting framing222into the opening of the screen224(and cavity therein) and securing the flap228to the screen224once the frame222is fully inserted. Preferably, the flap228is releasably secured using Velcro® or some other means. One skilled in the art would appreciate the multitude of different manners in which this may be accomplished including double stitching the flap228to the screen224, or using snaps, buttons, and the like. Velcro® is preferred because it provides a quick and easy method of removing and installing a new protective screen224in the event one is damaged by hail or worn out by the elements.

In the preferred embodiment, the protective screen224is shaped such that is not completely taut on the frame222. Some degree of slackness in the protective screen224allows it to perform substantially like a trampoline when hail strikes it. This provides an enhanced deflection of the hail while preserving the life of the protective screen224. However, a taut protective screen224may be used according to the present invention, but generally will not perform as well.

Turning toFIG. 2, the weather guard200is shown in its installed position. The protective panels220are installed generally by attaching them to the top of the housing102of the air-conditioning unit100. The protective panels220are supported on their lower ends by support rods230, which are secured to the lower portion of the housing102of the air-conditioning unit100.

In the preferred embodiment, the upper portion of the protective panel220is rotatably attached to the housing102of the air-conditioning unit100. This allows a user to alter the angle of the protective panel220relative to the condenser grill106of the air-conditioning unit100. Generally, an angle of 45 degrees is preferred, but this angle may need to be modified according to the characteristics of hailstorms in the particular geographic area in which the unit is installed. Using a protective panel220with a height equal to or greater than two thirds the height of the air-conditioning unit100has been found to provide optimal protection from hail and shading of the air-conditioning unit100. Also, support rods230of different length or adjustable length may be used to enhance the optimization of the angle at which the protective panels220are oriented.

Turning toFIG. 7, the protective panel220is secured to the upper housing102of the air-conditioning unit100by a p-clamp204and a fastener242. Preferably, two clamps are used to secure each end of the protective panel220. In the preferred embodiment, the p-clamp204and fastener242are attached to an upper housing110of the air-conditioning unit. This location is preferred, among other reasons, because air-conditioning units often have pre-existing holes in their upper housing such that a user need not drill a hole into the unit to install the protective panel220. Before tightening the fasteners242, the user should adjust the protective panels220to the desired angle.

FIG. 8illustrates the attachment of support rod230to the lower portion of the frame222of the protective panel220. The support rod230is secured by clamp244and fastener246. In the preferred embodiment, two support rods230(as shown inFIG. 2) are used to support each protective panel220. One or more rods230may be used to support the protective panels220. The opposite end of the support rods230are secured to the lower portion112of the housing102of the air conditioning unit100through another clamp248and a fastener250. Preferably, the drip railing (not shown) is the portion of the air-conditioning unit to which the support rods230are secured.FIG. 9illustrates the installation of the support rod230to the air-conditioning unit102. While a variety of clamps and brackets may be used, an electrical conduit standoff is preferred. As with upper portion of the protective panel, the lower end of each support rod230is preferably rotatably attached to the clamp248so that the angle of the support rod230and hence the position of the support panel220may be adjusted to suit a user's desires.

As shown inFIG. 3, a protective panel220can easily be lowered by removing the support rods230. This causes the protective panel220to hang substantially flush to the surface of the side of the air-conditioning unit100. This allows a repairman greater access to the air-conditioning unit100to repair or service it.

As shown inFIG. 2, a triangular protective panel260may also be installed. In the preferred embodiment (illustrated inFIG. 10), the triangular protective panel260includes a frame262and protective screen264and is constructed similar to the protective panel220. The frame262and protective screen262can be constructed of the same materials used to construct the frame222and protective screen224of the protective panel220. Holes266are also included to facilitate attachment of the triangular protective panel260to the protective panels220. A metal or rubber grommet (not shown) may be included with each hole to enhance its performance.

As shown inFIG. 10, commonly available tie wraps268are used to secure the frame of the triangular protective screen260and the protective screen220. One end of the tie wrap268is inserted into the hole266and the other end of the tie wrap268is wrapped around the frame222of the protective panel220. The tie wrap268is then pulled taut causing the triangular protective panel260to be secured to the protective panel220. The other side of the triangular protective panel260can be installed in a similar manner to the other protective panel220(not shown).

The primary advantage of the present invention is that it provides a relatively easy to install and relatively inexpensive apparatus for protecting air-conditioning units from damage caused by hail and other inclement weather conditions. Another advantage of the present invention is that the weather guard200may be quickly and easily adjusted to accommodate a variety of angles relative to the surface of the air-conditioning unit100to optimize protection in a variety of different geographic locations. Another advantage of the present invention is that it does not restrict airflow in and out of the air-conditioning unit. Yet another advantage of the preferred embodiment of the present invention is that it is constructed of non-metallic solar shade material, which in addition to protecting air-conditioning units from hail damage, shades the unit thereby lowering its temperature and enhancing performance.

The system and apparatus for protecting an air-conditioning unit described herein is relatively easy to install, relatively inexpensive, does not significantly resist air flow into or out of the air-conditioning unit, is adjustable, and attaches directly to the air-conditioning unit housing.