Abstract:
The apparatus is a heat exchange unit for cooling interior rooms of commercial and/or residential structures. The unit includes a compressor and blower mounted within a base. A lid of the base has an elongated heat exchange tube mounted thereon. The heat exchange tube has an interior liner with a coil structure mounted to the outside surface thereof. An outer liner enclosed the interior liner and associated coil structure. Both the interior and exterior liners are composed of a perforated metallic material. The vertical heat exchange tube is enclosed with a baffle at the top portion thereof. The baffle functions to force air moving upward to travel in an outward and downward direction toward the base and outside of the liners through the perforations. In an alternative embodiment, the vertical heat exchange tube may include a intermediate tube mounted between the interior and exterior tubes. The intermediate tube also has coils wrapped about the perimeters. In general, the unit with two liners is designed to be a lower capacity unit than the unit with three liners. Accordingly, the unit may be expanded for greater efficiency designs by increasing the surface area of the coil structure, and by serially connecting multiple units.

Description:
CROSS REFERENCE TO RELATED APPLICATION(S)  
       [0001]    This a Continuation-in-Part utility patent application of application Ser. No. 09/612,670, filed Jul. 10, 2000, entitled “Environmentally Adaptive HVAC Exterior Heat Exchange Unit”, now pending, which is a Continuation patent application of application Ser. No. 09,372,830 entitled “Environmentally Adaptive HVAC Exterior Heat Exchange Unit”, now U.S. Pat. No. 6,085,536. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Technical Field  
           [0003]    This invention relates to heat exchanger and air conditioner condenser units. More specifically, the present invention relates to an environmentally adaptive construction for the external unit of a HVAC unit.  
           [0004]    2. Description Of The Prior Art  
           [0005]    Conventional heat exchange units are generally round or square in shape. They are configured with a set of heat exchanger coils surrounding the compressor and blower units. As such, the configuration of the coils define the shape of the unit as a whole. Most coil structures include fins for providing increased heat dissipation surface to the coil structure. The increased surface area enhances the cooling effect of the coil structure and allows the heat exchange unit to achieve the desired efficiency and output. The fins are generally soldered onto the coil structure to become permanently affixed thereto. The process of soldering fins to the coil structure is cumbersome and expensive. Accordingly, it is desirable to design a novel coil structure for a heat exchange unit that eliminates the need for soldering fins to the coil structure.  
           [0006]    In addition to the design of the coil structure for efficiency and output purposes, it is also desirous to design a heat exchange unit that will not be an intrusive structure to the facility it is cooling. For example, most commercial and residential heat exchange units are situated in a rectangular or circular shaped container, which are placed adjacent to the structure they are cooling. A larger building will require a larger compressor unit and/or multiple units to sufficiently cool the interior spaces of the facility. It is often difficult to place external units in a location in relation to a building where the presence of the unit will not be intrusive. This can present obstacles to the full and effective use of the exterior spaces of a structure. In addition, large units are not only visually intrusive but can also create significant unwanted noise levels. Accordingly, it is therefore desirable to overcome the limitations of the prior art and to provide a unit which is efficient and has a camouflage appearance so as not to be directly noticeable to passers by.  
         SUMMARY OF THE INVENTION  
         [0007]    It is an object of the present invention to provide an environmentally adaptive external unit for an HVAC system which will blend visually with the surroundings while providing efficient and effective heat exchange.  
           [0008]    It is a further object of the present invention to provide an external HVAC unit which can be used to architecturally enhance the exterior of a structure. The unit includes a compressor to compress a refrigerant, a blower for circulating air over a coil structure and for circulating air through the housing, and a tube for delivering the compressed refrigerant to a heat exchanger tube. The heat exchanger tube is longitudinal and is mounted vertically to an exterior surface of the base of the housing. The heat exchanger tube includes a plurality of liners extending vertically from the base. The coiled structure is wrapped spirally about an exterior surface of an interior liner to provide a cooling surface.  
           [0009]    It is yet a further object of the present invention to provide a method of cooling an enclosed structure. A housing is provided for storing a compressor and a blower. A vertical heat exchange tube structure is mounted on a top exterior surface of the housing. The tube includes an interior liner with a coil structure wrapped spirally about its exterior surface. A compressed refrigerant is delivered from the compressor to the heat exchange tube to dissipate heat.  
           [0010]    Other features and advantages of this invention will become apparent from the following detailed description of the presently preferred embodiment of the invention, taken in conjunction with the accompanying drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]    [0011]FIG. 1 is a sectional view of an elongated heat exchange unit according to the preferred embodiment of this invention, and is suggested for printing on the first page of the issued patent.  
         [0012]    [0012]FIG. 2 is a sectional view of the vertical heat exchange tube.  
         [0013]    [0013]FIG. 3 is a sectional view of an alternative embodiment of the vertical heat exchange tube.  
         [0014]    [0014]FIG. 4 is a sectional view of the vertical heat exchange tube with a camouflage application. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
     Overview  
       [0015]    Most heat exchange units for either residential or commercial structures are stored within box type structures and are noticeable to passers by. In general, all components of the apparatus are stored within the box and operate therefrom. The purpose of the vertical heat exchange tube for the heat exchange unit of the invention is to both improve operating efficiency and to provide an aesthetically pleasing structure that may not be noticeable to most passers by.  
       Technical Background  
       [0016]    [0016]FIG. 1 is a sectional view of the heat exchange unit  10  showing the base  20  and the heat exchange tube  30 . The base  20  acts as a storage compartment for the components of the unit  10  with the exception of the heat exchange tube. The base  20  can be made of any suitable material that can store and protect the components therein from the environment, and prevent the base from developing rust. The inside walls and bottom surface of the base  20  may be lined with an insulating material, such as solid foam or other insulating material. A top portion of the base  20  includes a lid  22  for covering the base and enclosing the components of the unit  10  therein. In addition, the lid  22  acts as a support surface for the heat exchange tube  30 . Accordingly, the heat exchange unit comprises two external components, a base structure  20  for storing the hardware components of the unit  10  and a heat exchange tube  30  which is affixed to the lid  22  of the base and extends externally therefrom.  
         [0017]    The inside perimeter and/or circumference of the base  20  includes a liner  24  adapted to receive the components of the unit  10 . The liner  24  is placed adjacent to the inside perimeter of the base on both the vertical and bottom surfaces, and provides a protection surface for the internal components of the unit  10 . The vertical walls of the base  20  include a plurality of air intake apertures  26 ,  28  for providing air passage and circulation to the inside of the base  20 . The liner  24  includes reciprocating apertures  26   a ,  28   a  so as not to impede the entry of air into the inside of the base  20 .  
         [0018]    The compressor unit  40  is positioned on a bottom horizontal surface of the liner  24 . The compressor  40  is connected to a pair of suction lines  44  for delivering a refrigerant to the compressor  40 . Following compression, the refrigerant exits the compressor  40  and is delivered to the heat exchange tube via a coolant tube  46 . In the case of an additional coil structure, a second coolant tube  46   a  is provided. After the compressed refrigerant has run through the vertical heat exchanger tube  30 , it is delivered to an indoor coil evaporator, and subsequently recycled to the suction lines  44 . Accordingly, the refrigerant is cycled through a closed system to allow cooling of warm air.  
         [0019]    Adjacent to the compressor unit  40  is a blower  50 . The blower  50  is mounted within the base. In a preferred embodiment, the blower  50  is mounted to an inside surface of the lid  22 , and draws air from inside the housing and expels it vertically through the heat exchanger tube  30 . The blower  50  provides two essential functions. First, the blower circulates air over the tubes of the heat exchange coil  100 , if desired. Circulating air over the coil structure may enhance heat exchange. Second, the blower circulates air through the housing of the base  20 .  
         [0020]    As noted above, the housing unit includes a horizontal lid  22  for supporting the vertical heat exchange tube  30  mounted on an upper surface of the lid  22 , and for enclosing the remaining components of the heat exchange unit  10 . The lid  22  is secured to the housing by a mechanical component such as a hinge or a clip  42 . When the internal components of the unit  10  require servicing, the lid  22  may be rotated about the mechanical component. A pair of tubes  60  extend from the housing to the bottom surface of the lid  22  and allows for the lid to be lifted off of the housing without disconnecting the coolant tubes  46 . As the lid  22  is rotated about the hinges the length of the tubes  46  extend lengthwise. Accordingly, the mechanical components of both the interior portion of the housing and the lid allow the lid to be opened for servicing of the internal components of the unit  10  without disconnecting the lid from the housing  20 .  
         [0021]    [0021]FIG. 2 is a front view of the vertical heat exchange tube  30  of the preferred embodiment of the invention. The tube  30  is comprised of an inner tube  32 , an outer tube  34  and a coil structure  36 . The inner tube  32  is a liner preferably comprised of an aluminum perforated material. The outer tube  34  is also a liner preferably comprising of an aluminum perforated material. Both the inner tube  32  and the outer tube  34  may be made of a different material that allows the heat exchange to be conducted in an efficient manner. In a preferred embodiment, the inner tube  32  has a circumference of approximately seven inches, and the outer tube has a circumference of 7¾ inches. The difference between the circumference of the inner tube  32  and the outer tube  34  provides a spacing between the tubes, and allows a coil to be placed therein. The outside circumference of the inner tube  32  is wrapped with an Aluminum tube coil  38 . The wrapping extends from an area near the top of the inner tube  32  to an area near the top of the base  20 . A top portion of the heat exchange tube  30  includes a cover  70  for spreading air about the coil structure  38  in the channel  72  formed between the inner tube  32  and the outer tube  34 . As the blower  50  forces air upwards into the heat exchange tube  30 , the air enters the inner tube  32  and flows upward toward the cover  70 . Upon reaching the cover  70 , the air spreads out to the channel  72  formed between the tubes  32  and  34 . The return air transfers heat between the inner tube  32  and the outer tube  34 , and dissipates out through the apertures formed in the tubing material.  
         [0022]    The size of the coil structure  36  is limited by the width of the channel  72  formed between the inner tube  32  and the outer tube  34 . By wrapping the coil structure in a spiral configuration about the circumference of the inner tube, the need to weld any joints formed on the coils is mitigated. In a preferred embodiment, the heat exchange tube  30  ranges from about 24 inches to about 60 inches in height. The unit  10  ranges from a ½ ton unit which delivers approximately 6,000 BTU to a 3 ton unit which delivers 36,000 BTU for this given height. The output of the unit for the given height will depend upon the size of the coil and the size of the compressor. A 1½ ton unit will only require a coil structure with a ⅜ inch diameter, while a 3 ton unit will require multiple coil structures wrapped about the inner tube  32  and/or the outer tube  34 , wherein the coil structure has a ⅜ inch diameter.  
         [0023]    [0023]FIG. 3 is a front view of a further embodiment of this invention. The structure is similar to the unit  10  illustrated in FIG. 2, however this is a larger unit that can deliver a higher output. This unit  100  is a five ton heat exchange unit. This larger unit requires three tubes in the vertical tube exchange  110 . The first tube  112  is an inner tube similar to tube  32 . The outside surface of the tube is wrapped with a coil structure  120  in a spiral configuration. The coils extend from an area near the inner tube  112  to an area near the top of the tube  112  and adjacent to a cover  120 . Adjacent to the outside surface of the coil structure  120  of the inner tube  112  is an intermediate tube  114 . This tube is placed between the inner tube  112  and an outer tube  116 . The intermediate tube  114  also has a coil structure  122  wrapped in a spiral configuration about the outside surface thereof. Adjacent to the outside surface of the coil structure  122  of the intermediate tube  114  is the outer tube  116 . Each of the tubes  112 ,  114  and  116  are similarly designed. The liner tubes  112 ,  114  and  116  are each preferably comprised of a perforated metallic material that allows air to dissipated through the apertures. In a preferred embodiment the liner tubes  112 ,  114  and  116  are comprised of a metallic material, such as Aluminum. However, instead of Aluminum, the liner tubes may be made from another metallic material having suitable or similar quality. During operation, air from the blower is forced upward into the tube structure through the inside of the inner tube  112 . The air flows upward through the inner tube until it reaches the top cover  120 , which functions to spread the air about the coil structures  120  and  140  of both the inner tube  112  and the intermediate tube  114 . Accordingly, the two sets of coil structures together with the additional vertical tube of the unit provide for a greater capacity.  
         [0024]    Increasing capacity and efficiency of the unit of the preferred embodiment is not limited to increasing the quantity of vertical tubes. Rather, the unit may also be designed with a greater height. For example, a unit with a vertical heat exchange tube in excess of twenty four inches would reduce the liquid line and would increase efficiency. Such a unit would effectively have a greater length of coils wrapped about the inner tube  32 ,  112 , and possibly an intermediate tube  114 . However, when increasing either the height of the unit or the length of the coil structure, the increased capacity of the unit remains limited by the size of the compressor stored in the housing. Accordingly, the unit may include a height in excess of twenty four inches, or it may include a plurality of concentric elongated tubes with coils wrapped about the circumference of an inner tube, or combinations thereof.  
         [0025]    In addition, a single unit may be appropriate for a residential housing unit, and a larger single unit may be appropriate for a larger residential housing unit. Multiple units of the unit disclosed in the preferred embodiment may be serially connected to cool a larger structure. Accordingly, the unit of the preferred embodiment may be employed to cool residential or commercial structures.  
         [0026]    Different size units will require different size compressors for producing the output desired. It is known that the compressor and coolant pump can generate noise which may become unpleasant. The unit of the preferred embodiment is designed such that the base can be placed above a ground surface or buried into the ground to reduce its visible size and/or to reduce the noise associated with the compressor and coolant pump. Accordingly, the base may be placed underground with the heat exchange tube placed above the ground surface to reduce noise associated with operation of the unit.  
         [0027]    An aesthetic property of the unit, allows the heat exchange tube  30 ,  110  to be camouflaged, so that the unit may not be noticeable to passers by. FIG. 4 is an illustration of one form of camouflaging the heat exchange tube and unit. The heat exchange tube extends vertically from the upper surface of the lid  22  and is adapted to be covered by an artificial or natural shrubbery  200  which is placed around the tube  30 ,  110 . The shrubbery includes an inner cylindrical lining  150  with a diameter greater than the diameter of the outer tube  34 ,  116 . Portions of the shrubbery are secured to the lining, and may be designed to look like branches of a tree. Since thick branches, leaves, and/or needles may impede air flow within the heat exchange tube, the inner portions of the branches can be thinned to remove potential airflow obstructions. Furthermore, the base  20  may be placed in a large flower pot. Accordingly, when the flower pot is combined with the shrubbery, the unit  10 ,  100  looks like a potted plant and not like a beat exchange unit.  
       Alternative Embodiments  
       [0028]    It will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without departing from the spirit and scope of the invention. In particular, the coil structure may be comprised of multiple tubes of different sizes. For example, a ⅛ inch diameter coil may be employed, or multiple ⅛ inch diameter coils may be wrapped about the inner tube  32 ,  112  and possibly the intermediate tube  114 . Three ⅛ inch coils may be wrapped about the inner tube  32 ,  112 . Multiple coils provide an increased surface area for reaction, and thereby allows the refrigerant to get cooler quicker. In addition to modifying the unit to accommodate wrapping multiple coil structures about the outside circumference of the tube  32 ,  112 ,  114 , the unit may also include aluminum flakes applied to the outside surface of the coils. The flakes are affixed to the surface of the coils with a thermally conductive material, and function to help dissipate heat from the surface of the coils. Accordingly, by varying the size of the coils and the quantity of coils wrapped about the inner tube  32 ,  112  and intermediate tube  114 , the cooling efficiency of the unit may be modified.  
         [0029]    In addition to varying the size and quantity of the coil structure, the layout and placement of the coil structure about the inner tube  32 ,  112  and intermediate tube  114  may be modified. The preferred embodiment discloses wrapping the coils in a spiral configuration about the exterior surface of the inner tube  32 ,  112  and intermediate tube  114 . The spiral configuration alleviates the need to solder joints between breaks of the coil structure. However, the coil structure may be laid upon the inner tube  32 ,  112  and intermediate tube  114  in varying configurations that provide the necessary surface area to provide the desired efficiency and output of the unit. Accordingly, the scope of protection of this invention is limited only by the following claims and their equivalents.