Abstract:
A blower cover and an air conditioner using such blower. A rollable sheet is locked between two side plates by rollable connectors. A belt plate is secured between the side plates to lock the rollable sheet between the side plates. The belt plate also directs air from the blower. The blower cover can easily be assembled at a work site without welding or expert metal working. The blower cover is used in an air conditioner in which air is forced upwards from the blower and the air is directed into a heat exchange unit by one or more air deflectors. Another air deflector directs air coming out of the heat exchanger in an upwardly direction out of the air conditioner and this air deflector also directs any condensate downwards toward a drain system generally located below the heat air conditioner.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention relates to a method and apparatus for installing a cover for a blower of a heat exchange unit  
           [0003]    2. Discussion of the Related Art  
           [0004]    Prior art covers for the blowers of heat exchange units are generally made of metal stampings that are welded and/or screwed together. Such prior manufacturing methods require expert sheet metal craftsmanship, as well as welding skills. Since such expertise is required, prior art covers or blowers are generally manufactured at a central site. The prior art blower covers are generally manufactured as two or more separate parts that are assembled together after the separate parts of the cover surround a fan/motor unit. Since the prior art blowers are generally manufactured in a separate manufacturing site, rather than at the work site, the bulky blower assembly has to be shipped from the manufacturing site during which the blower cover may be easily damaged.  
           [0005]    In addition, since prior art blowers are usually of metal construction, they are susceptible to corrosion caused by moisture and pollutants, thus requiring frequent repairs. In general, prior art blower covers are very costly to manufacture as it requires expert sheet-metal craftsmanship, as well as good welding skills for the manufacture thereof.  
           [0006]    In Applicant&#39;s Korean Patent Application Number 10-1999-0028227, the document details a blower fan and housing that absorbs and decomposes air pollutants. This document discloses the use of certain materials for the fan and housing of a blower that absorbs or decomposes air pollutants. The Korean 10-1999-0028227 document specifies various types of materials that are suitable for use in a blower and can absorb or degrade air pollutants.  
           [0007]    A need exists to dramatically lower the cost of blower covers. A further need exists for blower covers that are resistant to corrosion and can absorb or decompose air pollutants. A further need exists for a blower cover that can be easily assembled at the work site without the requirement for expert knowledge, i.e., sheet-metal and welding skills.  
         SUMMARY OF THE INVENTION  
         [0008]    The present invention provides an apparatus and method for a blower cover of a heat exchange unit. The blower cover includes at least two side plates positioned substantially opposite one another, and a rollable sheet positioned between the two side plates. Two rollable connectors, one for each of the side plates, each including upper and lower walls that are parallel to each other and a rib that connects to and spaces apart the upper and lower walls so that each of the rollable connectors forms a substantially H-shaped cross-section. The upper wall of the rollable connectors include upper left and right legs, and the lower wall includes lower right and left legs. The legs of the rollable connectors are either positioned either to the left or right side of the rib. The upper right leg of the rollable connectors is generally longer than the lower right leg. The upper right leg of the connectors include a lip extension that extends from an open end of the upper right leg perpendicularly downwards, towards the lower right leg to form a substantially L-shaped cavity between the upper and lower right legs and the lip extension. A left cavity is formed by the rib and the upper and lower legs of the rollable connector. The edge portions of each of the side plates is secured in and along the L-shaped cavity of the rollable connectors. The side edges of the rollable sheet are each secured in the left cavities of the rollable connectors.  
           [0009]    The blower cover of the present invention solves the various problems associated with prior art blower covers. The apparatus and method of the present invention permits on-site manufacture of the blower covers without the requirement for expert skills.  
           [0010]    The blower cover of the present invention can be easily assembled by using rollable components, including the rollable sheet and the rollable connectors for connecting the sheet to the side plates. These components are easily transportable as well since they can be compacted by being rolled or coiled. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]    In order more fully explain the features and advantages of the present invention, the following preferred embodiments of a blower cover and assembly in an air conditioning unit are described, as examples only without any limitative character with reference to the accompanying drawings, in which:  
         [0012]    [0012]FIG. 1 is a perspective view of the blower cover of the present invention;  
         [0013]    [0013]FIG. 2 shows the attachment of an air director plate on the blower shown in FIG. 1;  
         [0014]    FIGS.  3 A- 3 C show various embodiments of the rollable connector;  
         [0015]    FIGS.  4 A- 4 C show partial cross sections of the assembled blower cover;  
         [0016]    [0016]FIG. 5 is a perspective view of the blower cover positioned around a motor and fan unit and secured in an air conditioner unit;  
         [0017]    [0017]FIG. 6 is a perspective view of a water drain system;  
         [0018]    [0018]FIG. 6A is a cross sectional view of FIG. 6 taken along lines  6 A- 6 A;  
         [0019]    [0019]FIG. 7 is a side view of the air conditioner unit of FIG. 5, shown with a wall section removed so that the heat exchanger, water drain system, and the blower are visible. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0020]    [0020]FIGS. 1 and 2 show perspective views of a blower cover that has been assembled. Two spaced apart side plates  3  are positioned substantially perpendicular to an imaginary longitudinal line  4 . The rollable sheet  7  is secured between the two side plates  3  by two rollable connectors  5 , each placed between each of the side plates  3  and the rollable sheet  7 . The side plates  3  each includes an open cavity  9  through which air is directed into the blower, which includes a motor and fan unit housed within the cover  1 . The side plates  3  include small holes through which various attaching devices, including bolts, can be inserted to position the motor and fan unit that is to be housed in the cover  1 .  
         [0021]    [0021]FIG. 2 shows an air deflector plate  13  attached to the side plates  3 .  
         [0022]    The air deflector plate  13  completes an outlet of the cover  1 .  
         [0023]    FIGS.  3 A- 3 C show perspective views of various embodiments of the rollable connectors  5 ,  5 A,  5 B. Each of the connectors  5 ,  5 A,  5 B include upper and lower walls  51 - 54  that are parallel to each other and a rib  55  that connects to and spaces apart the upper and lower walls  51 - 54  so that each of the connectors  5 ,  5 A,  5 B has a substantially H-shaped cross section. The upper wall includes an upper left leg  51  and upper right leg  53 . The lower wall includes a lower right leg  54  and a lower left leg  52 . The legs  51 - 54  are positioned substantially either to the left or right side of the rib  55 . The upper right leg  53  is generally longer than the lower right leg  54 . The upper right leg  53  includes a lip extension  56  that extends from the open end of the upper right leg  53  perpendicularly downwards towards the lower right leg  54  to form a substantially L-shaped cavity  57  between the upper and lower right legs  53 ,  54  and the lip extension  56 . A left cavity  58  is also formed in the rollable connector  5 ,  5 A,  5 B. The left cavity  58  is formed by the rib  55  and the upper and lower left legs  51 ,  52 . FIGS.  3 A- 3 C show various embodiments in which the lengths of the legs  51 - 54  and the lip extensions  56  vary in length as compared to one another. Further, it is envisioned that the dimensions of the ribs  55  can also be varied in order to accommodate varying dimensions of the side plates  3  and the rollable sheet  7 .  
         [0024]    [0024]FIG. 3C shows a lower lip extension extending from the right leg  54 . The lower lip extension  56 A is substantially parallel to the lip extension  56  of the upper right leg  53 .  
         [0025]    FIGS.  4 A- 4 C illustrate partial cross sections of the various embodiments of the blower cover  1 . The side plates  3  are positioned substantially perpendicular to the imaginary longitudinal line  4  (shown in FIG. 1). Each of the plates  3  have an edge portion  31  that are generally positioned on the outer periphery of the side plates  3 . The edge portion  31  of the plates that extends substantially parallel to the imaginary longitudinal line  4  and towards the other side plate  3 . The rollable connector  5 ,  5 A,  5 B is slid along its H-shaped cavity into the side plate  3 , such that the L-shaped cavity  57  is filled by the edge portion  31  of the plate  3 , along with portions of the outer peripheral of the plate  3 , as shown in FIGS.  4 A- 4 C. The rollable sheet  7  includes left and right side edges  73 . The right side edge  73  (shown in FIGS.  4 A- 4 C) is inserted into the left cavity  58  of the rollable connector  5 ,  5 A,  5 B. The left side of the cover  1  is assembled in the same manner as the right side portion of the cover  1  (as shown in FIGS.  4 A- 4 C).  
         [0026]    The assembly of the side plates  3 , rollable sheet  7 ,  7 A and the rollable connectors  5 ,  5 A,  5 B forms a substantially rigid structure The blower cover can further be strengthened by applying adhesive into the L-shaped cavity and the left cavity of the rollable connectors  5 ,  5 A,  5 B in order to bind the components. Alternatively, or in addition to the application of adhesives, securing devices, in the form of screws for example, may secure the side plates  3  to the rollable connector  5 ,  5 A,  5 B, and the rollable sheet  7  to the rollable connector  5 ,  5 A,  5 B, as well, as shown in FIGS. 4B and 4C.  
         [0027]    In FIG. 4C, the rollable sheet  7 A includes a central portion  71  and side edges  73 . The thickness of the central portion  71  is larger than that for the side edges  73 . The rollable sheet  7 A is shaped to be flush fit with the left side of the rollable connector  5 , as shown in FIG. 4C.  
         [0028]    It is preferred that the parts of the blower cover are non-corrosive. The rollable sheet  7 ,  7 A is preferably a plastic, fiberglass or metal sheet that is easily rolled and unrolled for easier transport. The side plates  3  are generally made of stamped metal sheets, but it is envisioned that the side plates  3  could just as well be made of injection-molded plastic or fiberglass, or other non-metal material. The rollable connectors  5 ,  5 A,  5 B is preferably made of flexible material, such as a plastic or fiberglass compound, which can easily be rolled and unrolled, for easy transportation.  
         [0029]    Further, it is known that certain materials (as disclosed in Korean Patent Application 10-1999-0028227) have very good absorption characteristics for absorbing air pollutants. It is preferred that the rollable sheet  7 ,  7 A includes material on its inner surface that faces the fan and motor assembly  9 A, to include material having such absorptive characteristics. Material that is suitable for the rollable sheet  7 ,  7 A, to be impregnated on its surface include germanium oxide, silica, alumina, ferrous oxide, calcium oxide, magnesium oxide, potassium oxide, mica, quartz, and zeolite. Similarly, it is also preferable that the rollable connectors  5 ,  5 A,  5 B also include such absorptive material in its construction. The material for absorbing air pollutants can also be placed onto the inside surface of the side plates  3  that face the motor and fan assembly  9 A. In addition, it is envisioned that the fan blades (not shown) of the fan and motor unit  9 A are made of such material that has absorptive characteristics for absorbing air pollutants. It is envisioned that the fan blades of the blower also include such material or materials selected from the group of materials, mentioned in regard to the rollable sheet  7 ,  7 A and rollable connectors  5 ,  5 A,  5 B.  
         [0030]    [0030]FIG. 5 shows an air conditioner unit  2  that includes the blower cover  1  secured therein, in addition to a water drainage system  31   1 , as well as a heat exchanger  21 . The blower includes a fan and motor unit  9 A covered by the cover  1 . FIG. 7 illustrates a side view of the air conditioner unit  2  with a side wall removed, so that the flow of air (indicated by the arrows) can be better illustrated. The blower which includes the fan and motor unit  9 A covered by the blower cover  1 , is positioned to expel air vertically upwards through the outlet  111 . A heat exchanger  21  is positioned to the right of the outlet  11  of the blower. The heat exchanger  21  includes both air entering and exiting faces  21 A,  21 B. Between the two faces of the heat exchanger  21  include passageways (not shown) for the air to travel from the air entering face  21 A and out of the air exiting face  21  B. Air from the blower is directed into the air entering face  21 A of the heat exchanger  21  by the upper and middle air deflectors  51 ,  53 . The air entering and air exiting faces  21 A,  21  B have upper and lower portions  212 - 215 .  
         [0031]    The upper air deflector  51  is attached to the upper portion  212  of the air entering face  21 A of the heat exchanger  21 . The upper air deflector  51  guides air exiting from the outlet  111  of the blower into the air entering face  21 A of the heat exchanger  21 .  
         [0032]    The lower air deflector  55  is positioned at or near the lower portion  215  of the air exiting face  21 B of the heat exchanger  21 . The lower air deflector  55  guides air exiting out from the air exiting face  21 B of the heat exchanger  21 , towards the outlet  27  of the air conditioner unit  2 . The lower air deflector  55  includes an upper surface  552  on which condensed water may accumulate. Additionally, water can condense on other parts (including inner surface of side wall  23 B) of the air conditioner unit  2 , and the lower air deflector  55  is positioned to receive the condensated water and direct the water downwards on its upper surface  552 , assisted by gravity. The condensated water is directed from the lower air deflector  55  into a water drain system  31 . The water drain system  31  receives the condensed water from the lower air deflector  55  and expels the water via a drain  395 .  
         [0033]    The middle air deflector  53  is attached between the top and bottom portions  212 ,  213  of the air entering face  21 A of the heat exchanger. The middle air deflector  53  allows for a more even distribution of air from the blower into the air entering face  21 A. In the absence of the middle air deflector  53 , most of the air exiting the blower would be directed towards the top portion  212  of the air entering face  21 A, thus reducing the efficiency of the heat exchanger  21 .  
         [0034]    The air conditioner unit  2  includes left and right side walls  23 A,  23 B. The upper air deflector  51  is secured to the left side wall  23 A, and the lower air deflector  55  is secured to the right side wall  23 B.  
         [0035]    As shown in FIG. 6 the water drain system  31  includes a pan  33  which is positioned below and along the longitudinal length of the heat exchanger  21 . The pan  33  includes lateral projections or heat exchanger supports  392  on which the heat exchanger can be placed, and a bottom  331  which is recessed from the horizontal. Condensed water from the lower air deflector  55  is directed into the bottom  331  of the pan  33 . Since the bottom  331  of the pan  33  is recessed, water is directed down along the recessed bottom  331  of the pan  33 , into a water collector  39 . The water collector  39  is a container having a bottom wall  391  and a drain  395  into which water collected on the bottom wall  391  is directed into. The drain  395  directs water out of the air conditioner device  2 .  
         [0036]    In one embodiment, the pan  33  may include a lateral lip  333 , as shown in FIG. 6, onto which the lower air deflector  55  may be attached to via a connector device  551  which fastens itself onto the lateral lip  333 . The lateral lip  333  is preferably recessed from the horizontal in order to direct condensed water from the lower air deflector, over the lateral lip  333  and into the pan  33 . FIG. 6 and  6 A show a support device  4 A for the water collector  39 . The support device  4 A includes a L-shaped support  41  having a support bore  411  and an elliptical roller  43  having a roller bore  431  rests on the L-shaped support  41 . A pin  45  having a pin head with a dimension larger than the roller bore  43  such that when the pin head is caught on the top of the roller bore  431  after the pin  45  penetrates through the roller bore  431  and the support bore  411  to lock the support device  4 A in place. To unlock the support device  4 A, the pin  45  is removed from the roller  43  and the L-shaped support  41  and the roller  43  is rotated 90 degrees after the water collector  39  is urged upwards.  
         [0037]    The present invention is by no means restricted to the above-described preferred embodiments, but covers all variations that might be implemented by using equivalent functional elements or devices that would be apparent to a person skilled in the art, or modifications that fall within the spirit and scope of the appended claims.