Abstract:
Disclosed are apparatus, kits and methods for cleaning an air conditioning unit having an air conduit defined by at least one wall with a hole therein the allows a cleaner to be introduced between a fan and a heat exchanger of the unit positioned along the conduit. In one embodiment, the apparatus includes a resilient female component that is manually inserted into the hole. The female component has an opening therein that provides access to the conduit between the fan and the heat exchanger. A male component is removably received within the female component and it has a passageway therein that allows the cleaner to flow therethrough into the conduit. A plug is manually inserted into the opening upon removal of the male component. In another embodiment of the apparatus, a one way valve is attached to the wall at a point that allows a cleaner to be introduced between the by fan and the heat exchanger of the unit, and a connector attached to a container of cleaner is removably attached to the one way valve. The connector, upon being attached to the one way valve, opens the valve. Upon being detached from the one way valve, the valve automatically opens. The kits hold the different pieces of the apparatus for assembly and connection to the air conditioning unit.

Description:
[0001]    RELATED APPLICATION  
         [0002]    This application is a utility application based on U.S. provisional patent application Ser. No. 60/136,689, entitled “Air Conditioning Cleaning Apparatus, Kit, &amp; Method,” filed May 28, 1999.  
     
    
     
       BACKGROUND OF THE INVENTION  
         [0003]    In U.S. Pat. Nos. 5,664,423 and 5,737,937 there are described systems for introducing a cleaning fluid into an automotive air conditioning unit. These systems require a nozzle to be inserted into the air steam flowing through the automotive air conditioning unit. This nozzle is connected through tubing to retainer structures within the driver/passenger compartment of the automotive vehicle into which the nozzle end of a container of cleaning fluid is inserted. These prior art systems contemplate reusing the container several times and are complex and expensive to install.  
         SUMMARY OF THE INVENTION  
         [0004]    This invention comprises an apparatus for, and methods of, cleaning an air conditioning unit, and kits used in connection with cleaning an air conditioning unit. The air conditioning unit has an air conduit defined by at least one wall with a hole therein that allows a cleaner to be introduced between a fan and a heat exchanger of the unit positioned along said conduit.  
           [0005]    The apparatus includes a two-component connector. In one embodiment of the apparatus, a male and female component are employed. The female component is resilient and it is manually inserted into the hole in the wall of the air conditioning unit by compressing it upon insertion into the hole. This female component has an opening therein that provides access to the conduit between the fan and the heat exchanger. The male component is received within the opening in the female component. In this one embodiment, it is removably attached to the female component. This male component has a passageway therein that allows cleaner to flow therethrough into the conduit. Typically, the connector is removed from the hole in the wall and a plug is manually inserted into this hole. In this one embodiment, the male component is removed from the female component and the plug is inserted into the opening in the female component upon removal of the male component from the female component.  
           [0006]    In the preferred embodiment of the apparatus of this invention, the first component is manually inserted into the hole in said wall, and it has a passageway and first and second ends. The first end extends into the wall and the second end extends outward from the wall. The passageway has an open mouth at its first end in communication with the conduit. The second component is disposed within the first component and its also has a passageway and first and second ends. The first end of the second component is connected to the second end of the first component and positioned inward of the open mouth of said first component and terminates at a position outward from the wall. The second end of the second component, which is also outward from the wall, is adapted to be placed in communication with a source of cleaner. Consequently, the cleaner upon being introduced flowing through the passageway in the second component and then through the passageway in the first component and out the open mouth into the conduit.  
           [0007]    In another embodiment of the apparatus of this invention, a one way valve is permanently installed in the hole in the wall of the air conditioning unit. A connector at the discharge end of the container of cleaning fluid upon being forced into the one way valve, opens this valve to allow fluid to enter the air conditioning unit. Upon, detaching the connector from the one way valve, the valve automatically closes and remains in the wall of the air conditioning unit available for subsequent use.  
           [0008]    The methods of this invention provide for cleaning an air conditioning unit having an air conduit defined by at least one wall and a fan and a heat exchanger of the unit positioned along said conduit.  
           [0009]    One method includes the steps of:  
           [0010]    (a) forming a hole in the wall positioned to allow a cleaner to be introduced into the conduit between the fan and the heat exchanger,  
           [0011]    (b) inserting into the hole a female component of a two-component connector, said female component having a opening therein that provides access to the conduit between the fan and the heat exchanger,  
           [0012]    (c) inserting into the opening in the female component a male component of the two-component connector, said male component being removably received within the female component and having a passageway therein that allows a cleaner to flow therethrough into the conduit,  
           [0013]    (d) feeding a cleaner into the conduit through the male component while said male component is inserted into the female component,  
           [0014]    (e) removing the male component from the female component after feeding cleaner into the conduit, and  
           [0015]    (f) upon removal of the male component from the female component inserting a plug into the opening in the female component.  
           [0016]    A second method includes the steps of:  
           [0017]    (a) forming a hole in the wall positioned to allow a cleaner to be introduced between the fan and the heat exchanger,  
           [0018]    (b) inserting into the hole a one way valve,  
           [0019]    (c) attaching to the valve to open said valve a connector on a container of a cleaner,  
           [0020]    (d) discharging the cleaner from the container through the connector and the valve into the air conditioning unit, and  
           [0021]    (e) detaching the connector from the valve with said valve automatically closing upon the connector being disconnected. The valve remains in place after detaching the connector.  
           [0022]    A third method includes the steps of:  
           [0023]    (a) forming a hole in the wall positioned to allow a cleaner to be introduced into the conduit between the fan and the heat exchanger,  
           [0024]    (b) inserting into the hole a connector having first and second components,  
           [0025]    said first component having a passageway and first and second ends, said first end extending into the wall and said second end extending outward from the wall, said passageway having an open mouth at said first end in communication with the conduit, and  
           [0026]    said second component being disposed within the first component and having a passageway and first and second ends, said first end of the second component being connected to the second end of the first component and positioned inward of the open mouth of said first component and terminating at a position outward from the wall, and  
           [0027]    (c) placing said second end of the second component into communication with a source of cleaner, said cleaner upon being introduced flowing through the passageway in the second component and then through the passageway in the first component and out the open mouth into the conduit.  
           [0028]    The kits each include a connector and a plug used in connection with cleaning an air conditioning unit having a wall with a hole therein. Preferably, the kits also include a container of cleaning fluid with an outlet adapted to be removably attached to the connector.  
           [0029]    In one embodiment of the kit of this invention, the kit includes a connector having a male component having has a passageway therein and a female component having an opening therein. The male component is within, or placed within, the opening in a female component. The female component is adapted to be fitted snugly ill the hole in the wall of the air conditioning unit. With the female and male components connected and the female component in the hole, and the connector in communication with the container, upon release of the cleaning fluid from the container, the fluid flows through the passageway in the male component and through the opening in the female component into the air conditioning unit. If the male component is removably attached to the female component, the plug is adapted to be inserted into the opening in the female component. If the entire connector is removed from the hole in the wall, the plug is inserted directly into the hole.  
           [0030]    In another embodiment of the kit of this invention, it includes a valve fitting adapted to be fitted snugly into a hole in the wall of the air conditioning unit and a container of cleaner. The valve fitting includes a one way valve, and the container has a connector adapted to be connected to the one way valve.  
       
    
    
     DESCRIPTION OF THE DRAWING  
       [0031]    The preferred embodiments of this invention, illustrating all its features, will now be discussed in detail. These embodiments depict the novel and nonobvious air conditioning cleaning apparatus, kits, and methods of this invention as shown in the accompanying drawing, which is for illustrative purposes only. This drawing includes the following figures (FIGS):  
         [0032]    [0032]FIG. 1 is a schematic view of an automotive air conditioning unit employing the first embodiment of the cleaning apparatus of this invention.  
         [0033]    [0033]FIG. 1 a  is a perspective view of a kit holding the major components of the first embodiment of this invention for delivering cleaner to the air conditioning unit.  
         [0034]    [0034]FIG. 2 is a perspective view of one wall of the automotive air conditioning unit shown in FIG. 1 with a grommet of a connector used in this invention force fitted into a hole drilled in this wall.  
         [0035]    [0035]FIG. 3 is a cross-sectional view taken along line  3 - 3  of FIG. 2.  
         [0036]    [0036]FIG. 4 is a side elevational view, partially in cross-section, showing the male component of the connector shown in FIG. 1 being attached to one end of a hose that is attached to a container of cleaner.  
         [0037]    [0037]FIG. 5 is a cross-sectional view showing the male component of the connector shown in FIG. 1 attached to the female component of the connector.  
         [0038]    [0038]FIG. 6 is a cross-sectional view taken along line  6 - 6  of FIG. 4.  
         [0039]    [0039]FIG. 7 is a cross-sectional view taken along line  7 - 7  of FIG. 4.  
         [0040]    [0040]FIG. 8 is a perspective view of a second embodiment of this invention employing a different type of connector than that depicted in FIGS. 1 through 7.  
         [0041]    [0041]FIG. 9 is a cross-sectional view of the male component of the connector shown in FIG. 8.  
         [0042]    [0042]FIG. 10 is a schematic view of an automotive air conditioning unit employing the third embodiment of the cleaning apparatus of this invention.  
         [0043]    [0043]FIG. 11 is perspective view, with sections broken away, of the one way valve fitting used in the third embodiment of this invention, showing a screw on attachment for placing the fitting in communication with a container of cleaner.  
         [0044]    [0044]FIG. 11 a  is an enlarged fragmentary view taken along line  11   a  of FIG. 11.  
         [0045]    [0045]FIG. 12 is perspective view similar to that of FIG. 11, with sections broken away, of the one way valve fitting used in the third embodiment of this invention, showing a barbed end piece which is force into the hose coming from the container of cleaner.  
         [0046]    [0046]FIG. 13 is a cross-sectional view of the valve fitting showing the valve ill a closed position.  
         [0047]    [0047]FIG. 14 is a cross-sectional view taken along line  14  of FIG. 1  3  showing the valve in an open position.  
         [0048]    [0048]FIG. 15 is an exploded cross-sectional view showing a forth embodiment employing a valve fitting different than that of the third embodiment.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0049]    First Embodiment  
         [0050]    As shown in FIG. 1, the first embodiment of this invention, apparatus  10 , includes a conventional automobile air conditioning unit  12  which is depicted in substantially the same manner as illustrated in U.S. Pat. No. 5,737,937. The apparatus  10  comprises a system for delivering a foaming cleaner to the interior of the automobile air conditioning unit  12 . As shown in FIG. 1 a , the major components of the appartus are retained in a kit  14 , for example, including the following: (1) a container  16  of foaming cleaner, (2) a two-component connector  18  having a female component  20  and a male component  24 , (3) a flexible hose  28  that preferably is transparent and has a length of from about 1 to about 2 feet, (4) a rubber stopper or plug  30 , and (5) installation instructions (not shown). These components of the kit  14  are assembled into a package held together with a rubber band  14   a , although other type of packaging such as, for example, boxes and baggies may be employed. An installer drills a hole  32  (FIG. 5) about ⅜ inch in diameter into one wall  34  of the air conditioning unit  12  at about midway between the air conditioning unit&#39;s fan  12   a  and an evaporator/heat exchanger  12   b . The lower wall  34  is used only for illustration, since any wall providing easy access would be suitable.  
         [0051]    As illustrated in FIGS. 2 and 5, the female component  20  of the connector  18  has two parts: a rubber grommet  21  and a tubular component  22 . The rubber grommet  21  has an opening  20   a  (FIG. 2) with a passageway  22   a  therein (FIG. 7). It is inserted into the wall  34  so that it is downstream of the air inlet  12   c  and next to the fan  12   a  which pulls air into the air conditioning unit  12  through the inlet. The rubber grommet  21  has extending through it the opening  20   a  which has a smooth internal surface  20   b.  This grommet  21  is force-fitted into the hole  32  in the wall  34  and is deformed or compressed upon insertion into the hole. It has an annular groove  20   c  (FIG. 3) about its distal end  20   d.  This distal end  20   d  is compressed as the installer inserts it into the hole  32 . Upon the distal end  20   d  passing through the hole  32  in the wall  34 , it expands and the rim  34   a  of the hole is retained in the groove  20   c.    
         [0052]    As depicted in FIG. 1, during normal operation of the air conditioning unit  12 , the plug  30  is pushed or force fitted into the opening  20   a  in the grommet  21 . During cleaning of the air conditioning unit  12 , this plug  30  is removed and the tubular component  22  of the connector  18  is pushed into the opening  20   a  in the grommet  21 . As best shown in FIGS. 4, 5,  6  and  7 , this tubular component  22  comprises a cylindrical wall  22   a  with a knurled surface  22   b , an open distal end  22   c  and an open proximal end  22   d  with an annular flange  22   e  that acts as a stop. The cylindrical wall  22   a  forms a passageway or tunnel  40  with a diameter that is only slightly less than ⅜ inch, and it has opposed slots  22   f  and  22   g  in it that allow the cylindrical wall to decrease in diameter as the tubular component  22  is pushed and force-fitted into the opening  20   a  in the grommet  21 . The knurled surface  22   b  improves the grip between the grommet  21  and the tubular component  22  upon engagement. The distal end  22   c  of the tubular component  22  may extend slightly beyond the distal end  20   d  of the grommet  21  as shown in FIG. 5. The inside surface (not shown) of the cylindrical wall  22   a  at the proximal end  22   d  is threaded.  
         [0053]    As shown in FIG. 4, the male component  24  has a passageway  24   a  extending along its longitudinal axis. The passageway  24   a  has open opposed ends  24   b  and  24   c , with a raised stop element  24   d  about midway between these ends. The diameter of this passageway  24   a  is substantially smaller than the diameter of the tunnel  40  in the tubular component  22 . For example, the diameter of the passageway  24   a  is about {fraction (1/16)} to ⅛ inch when used with a tubular component  22  having an inside diameter of about ⅜ inch (the tunnel diameter). The distal end  24   b  of the male component  24  is threaded and it screws into the proximal end  22   d  of the tubular component  22 . The proximal end  24   c  of the male component  24  is force fitted into an open end  28   a  of the hose  28  that is connected to the container  16  of cleaner. Upon connecting the male component  24  and female component  20 , the distal end  24   b  of the male component  24  terminates at or near the exterior of the wall  34  of the air conditioning unit  12 . This male component  24  does not extend into the air conditioning unit  12 . When the foaming cleaner is discharged from the container  16 , it flows as a stream of fluid through the passageway  24   a  and out the distal end  24   b , through the tunnel  40  formed by the cylindrical wall  22   a  of the tubular component  22 , and into the air conditioning unit  12 .  
         [0054]    With the connector  18  installed as shown in FIG. 5, upon pressing a control button  16   a , or similar structure on the container  16 , the foaming cleaner exits a nozzle  16   b , flows through the hose  28  and coupled together male component  22  and female component  20 , and enters the air conditioning unit  12 . It flows through the passageway  24   a  in the male component  24 , exiting the passageway  24   a  at the distal end  24   a  as a compact stream that passes through the tunnel  40  formed by the cylindrical wall  22   a  of the male component  22 . This stream upon passing through the tunnel  40  exits the distal end  22   c  and is captured by the stream of air flowing through the air conditioning unit  12  and is mixed therewith. The entire contents of the container  16  (the foaming cleaner) are delivered into the interior of the air conditioning unit  12  while the hose  28  is attached to the connector. The foaming cleaner is delivered with sufficient force to disperse it adequately in the air stream flowing through the air conditioning unit  12 .  
         [0055]    The tubular component  22 , while attached to the male component  24 , is removed from the grommet  21  when the entire contents of the container  16  have been discharged. The plug  30  is then inserted into the opening  20   a  in the grommet to prevent the foaming cleaner or other material from escaping from the air conditioning unit through the opening  20   a . The empty container  16  is then discarded. The assembly of the tubular component  22  and the male component  24  may be disconnected from the hose  28  and used repeatedly with another container of cleaner. In such a case, the plug  30  is removed and the assembly of the tubular component  22  and the male component  24  is reinserted into the open end of a flexible hose extending from another full container of cleaner.  
         [0056]    Second Embodiment  
         [0057]    The second embodiment of this invention, the apparatus  50 , is also used with a conventional air conditioning unit  12  such as depicted in FIG. 1. Its major components are retained in a kit (not shown) similar to that depicted in FIG. 1 a , for example, a box holding (1) a container  16  of foaming cleaner, (2) a two-component connector  54  having a female component  54   a  and male component  54   b , (3) a plug  30 , (4) a hose  28 , and (5) installation instructions (not shown). As shown in FIG. 8, an installer drills a ⅜ inch diameter hole  56  into an easy accessible wall of the air conditioning unit  12 , for example, the lower wall  34 , at about mid-way between the fan  12   a  and evaporator/heat exchanger  12   b . The female component  54   a  of the connector  54  is inserted by force fitting it into this hole  56  so that it is downstream of the air inlet  12   c  next to the fan  12   a  that pulls air into the air conditioning  12  unit through an inlet. The female component  54   a  is made of brass and is in the shape of a hollow cylinder. Its distal end  59  has a pair of opposed slots  60  and  62  (shown in phantom) in it that allows its cylindrical wall distal end  59  and inserts it into the hole  56  in the wall  34  of the air conditioning unit  12 . Upon releasing the distal end  59 , the cylindrical wall  64  of the female component  54   a  expands and the rim  56   a  of the hole  56  in the wall is grasped between two annular ribs  66  and  68  along the perimeter of the distal end  59  of the female component.  
         [0058]    The interior  69  of the cylindrical wall  64  of the female component  54   a  at its proximal end  70  is threaded. Like the first embodiment, during normal operation of the air conditioning unit, a plug  80  (FIG. 8A) is inserted into an open passageway  71  extending through the female component  54   a . In this second embodiment, the plug  80  is made of brass and it is treaded so that it may be screwed into the proximal end  70  of the female component  54   a . During cleaning, this brass plug  80  is removed by unscrewing it and the male component  54   b  of the connector  54  is screwed into the proximal end  70  of the female component  54   a .  
         [0059]    This male component  54   b  is made of brass and it has a passageway  72  (FIG. 9) extending along the its longitudinal axis. The passageway  72  has open opposed ends  72   a  and  72   b . The exterior  76  of the male component is threaded to enable it to be attached and detached by screwing and unscrewing it into the proximal end  70  of the female component  54   a . The open distal end  72   a  of the male component  54   a  is along the inside of the lower wall of the air conditioning unit when the male component has been screwed into the passageway  71  of the female component  54   a . Prongs  78  surrounding the open proximal end  72   b  of the male component  54   b  are pushed into one end of the flexible hose  28  that has its other end attached the nozzle  16   b  of the container  16  of foaming cleaner.  
         [0060]    With the connector  54  installed as shown in FIG. 8, upon pressing the control button  16   a  on the container, the foaming cleaner enters the air conditioning unit  12 . The entire contents (the foaming cleaner) of the container  16  are delivered into the interior of the air conditioning unit  12  while the hose is attached to the assembled connector  54 . The male component  54   b  is disconnected from the female component  54   a  when the entire contents of the container have been discharged. The brass plug  80  is then screwed into the proximal end  70  of the female component  54   a  to prevent the foaming cleaner or other material from escaping from the air conditioning unit  12  through the female component. The empty container is then discarded. The female component  54   a  of the connector  54  may be used repeatedly by removing the plug  80  and reinserting another male component that is connected by a flexible hose to another full container of cleaner.  
         [0061]    Third Embodiment  
         [0062]    The third embodiment of this invention, the apparatus  90  depicted in FIG. 10, employs a one way valve fitting  92  (similar to a grease fitting) installed in the lower wall  34  of the air conditioning unit  10  between its fan  12   a  and evaporator/heat exchanger  12   b . A hole  94  (FIG. 11) is drilled into the lower wall  34  and the valve fitting  92  is screwed into position. The valve fitting  92  is downstream of the air inlet  12   c  next to the fan  12   a  that pulls air into the air conditioning unit through an inlet. Once this valve fitting  92  is installed it may be used repeatedly. With the hose  28  connected to the valve fitting  92 , it opens as the foaming cleaner exits the container  16  an flows through the hose  28  into the fitting. The fitting  92  includes a one way valve  96  that allows the foaming cleaner to enter the air conditioning unit  10 . Upon pressing the control button, with the hose  28  attached to the valve fitting  92 , the entire contents of the container  16 , the foaming cleaner, is delivered through the valve  96  into the interior of the air conditioning unit  10 .  
         [0063]    As best shown in FIG. 11, the valve  96  has a tubular wall  96   a  that fits snug within a passageway  98   a  extending through a grommet  98  that fits within the hole  94   a . As best shown in FIG. 11 a , the exterior surface of the tubular wall  96   a  is knurled so that this knurled surface grips firmly the interior of the passageway  98   a  in the grommet  98 . As shown in FIG. 11, there may be a threaded connector  94  at the end of the hose  28 . This threaded connector  94  screws onto the open, threaded end  96   b  of the wall  96   a  to connect the hose  28  to the fitting  92 . Alternately, as shown in FIG. 12, the tubular wall  96   a  may terminate in a barbed end  96   c , and the hose with any connector may be directly attached to this barbed end.  
         [0064]    Housed within the tubular wall  96   a  is a coiled spring  100  and seated at one end of the spring is a ball  102 . The spring  100  normally urges the ball  102  into contact with a seat  111   a  near the open end  96   b  or  96   c  of the tubular wall  96   a  to close this open end. With the hose  28  extending from the container  16  connected to the fitting  92 , discharging the contents of the container causes the foaming cleaner to push against the ball  102  and compress the spring  100  as shown in FIG. 14, opening the valve  96  and allowing the entire contents of the container to flow into the air conditioning unit  10 . When the delivery hose  28  is disconnected from the valve fitting  92 , the valve  96  in the fitting closes automatically, preventing the foaming cleaner or other material from escaping from the air conditioning unit  10  through the valve. The empty container  16  is then discarded. This third embodiment initially comes in a kit as discussed above.  
         [0065]    Forth Embodiment  
         [0066]    As shown in FIG. 15, the forth embodiment, the apparatus  120 , includes a brass valve  122 , similar to valve  96  in that it has a tubular wall  96   a  enclosing a spring  100  and ball  102  at the end thereof that is normally seated on a seat  111  at the end  122   a . The ball  102  compresses the spring and opens the valve  122  in response to cleaner flowing from the container  16 . The one end  122   a  of the tubular wall  96   a  is barbed so that the hose  28  without any connector may be forced over this end  122   a . There is a raised annular stop element  123  between the end  122   a  and the end  122   b  with a pin  127  partially extending into the valve  122  that serves as stop for the spring  100 . The valve  122  has at the end  122   b  a brass insert  124  having a threaded exterior surface  124   a . The brass insert  124  is screwed into the tubular component  22  which in turn is forced into the grommet  21 . The valve  96  functions as discussed previously. After using, the assembly of the brass insert  124  and the valve  122  may be reused. In this embodiment the brass insert  124  is the male component and its one end  124   b  is positioned outward from the wall  34  when it is placed within the female component comprising the grommet  21  and the tubular component  22 .  
         [0067]    General  
         [0068]    In all these embodiments of this invention, no nozzle is positioned inside the air conditioning unit  12 , and no such nozzle is needed or used, because the foaming cleaner is delivered with sufficient force to disperse it adequately in the air stream flowing through the air conditioning unit. In fact, the fluid cleaner in all these embodiments is discharged either at or from outside the wall  34  and flows through the wall into the interior of the air conditioning unit  10 . The container  16  is not placed in any type of apparatus for ejecting the contents of the container into the automobile air conditioning located in the driver&#39;s/passengers&#39; compartment of a vehicle employing the air conditioning unit. Although the male and female components in these embodiments have been depicted a separate elements that are detachable, it is possible that they may be integrated as a unitary structure. In some instances, they have been made of metal, but they may also be formed from other material such as, for example, plastic.  
       SCOPE OF THE INVENTION  
       [0069]    The above presents a description of the best mode contemplated of carrying out the present invention, and of the manner and process of making and using it, in such full, clear, concise, and exact terms as to enable any person skilled in the art to which it pertains to make and use this invention. This invention is, however, susceptible to modifications and alternate constructions from that discussed above which are fully equivalent. Consequently, it is not the intention to limit this invention to the particular embodiments disclosed. On the contrary, the intention is to cover all modifications and alternate constructions coming within the spirit and scope of the invention as generally expressed by the following claims, which particularly point out and distinctly claim the subject matter of the invention: