Patent Publication Number: US-2023144012-A1

Title: Line Set Cover

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Patent Application Ser. No. 63/276,270 which is hereby incorporated by reference and made a part hereof. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to a cover for air conditioning (“HVAC”) lines exiting a structure. More particularly, this invention relates to a protection cover for pipes, conduits and wires that exit a structure and extend from interior HVAC equipment to outdoor HVAC equipment. 
     BACKGROUND OF THE INVENTION 
     In closed HVAC systems insulated pipes and conduits run from an indoor HVAC area, such as a furnace and air handler in the attic or basement of a structure to an outdoor HVAC compressor, for example. As such, good insulation for optimal energy efficiency and also protecting the pipes and conduits from the outdoor environment (e.g., wind, ultraviolet exposure, rain, snow, bugs and so forth) is needed. If the pipes, conduits and wires (may be referred to collectively hereafter as “line set”) are not adequately protected, particularly at the opening of the structure where the line set exits the structure, the end result may be a degradation in the efficiency of an HVAC system causing higher energy consumption as the equipment works harder and longer. 
     Many installers use non-uniform and substandard products and methods to seal the opening of the structure where the line set penetrates the structure. For example, soft foamed polymer fillers and adhesive tapes are sometimes used as insulation at the opening of the structure. Exposure to the outdoor environment often causes these types of penetration closures to fail. In addition, they are not aesthetically pleasing. Because of the different sizes of pipes, conduits and wiring and the inclusion in some multi-unit buildings of multiple line sets going through an opening, it is difficult for the installer to adequately seal each line set in a uniform and optimum manner. Doing so in an aesthetically pleasing manner is even more difficult. Therefore, there is a need for a line set cover at the exit point from the structure to accommodate single or multiple line sets in a quick, efficient, and aesthetically pleasing manner. 
     Prior attempts at uniform methods include recess boxing where the installer fabricates a metal box that is then embedded into the exterior wall. The line set is passed through the box and the installer then seals all around the box with a urethane foam or some other sealant. Other prior attempts at uniform efforts include single inlet roof flashings. These various methods have both aesthetic and efficacy issues. In addition, Airex has attempted to solve this problem with their Titan outlet product (http://www.airexmfg.com/titan/) and see U.S. Pat. Nos. 9,091,377; 9,523,200; 9,651,174; and 10,422,134. However, these products still do not accommodate the number and frequently odd angles of the line sets exiting the structure. Also, these products do not easily accommodate an existing HVAC outdoor unit with it existing line set, particularly if the installer needs to disconnect the pipes, conduits and wires and then reconnect after the prior art cover installed. 
     Accordingly, there is a need for a uniform apparatus and method to install a line set through an exterior penetration in a structure which is easy to install and protects both the line set and the interior of the building using the cover assembly. The cover assembly should be highly energy efficient (i.e., minimal air leakage) and should not depend on foam fillers, adhesives, or tape. The cover should easily accommodate unusual line set angles leaving the structure. Also, the cover should be flexible enough to aesthetically cover both single and multiple line sets and line sets of different shapes and sizes. 
     SUMMARY OF THE INVENTION 
     The present invention relates to an HVAC line set cover that fits over an opening which penetrates the outside wall of a structure and a portion of the line set adjacent to the outside wall penetration. The line set cover surrounds both the exposed line set and the exterior wall penetration to protect both that portion of the line set while also preventing the outside environment from having access to the interior of the structure through the outside wall penetration. 
     In at least one embodiment there is a cover adapted for mounting on the outside wall of a building to receive conduits, pipes, or wiring (e.g., line sets). The cover comprises a first face plate and a second face plate each having a partial hollow cone shaped protrusion. Each protrusion includes a proximal end at the face plate and a corresponding distal end away from its face plate. The two face plates are adapted to pivot about a point of rotation so that when the two face plates are joined, a completed hollow cone protrusion is formed. The cover also includes a sleeve membrane having a proximal end and a distal end and first and second edges, each edge extending between a proximal and distal end of the sleeve. A portion of the proximal end of the sleeve is fixed to the distal end of the first plate so that when the face plates are closed the sleeve may be wrapped around the conduits and wiring forming a closed cone shaped sleeve. 
     At least a portion of the proximal end of the sleeve is non-detachably attached to the distal end of the protrusion for the first face plate and a portion of the proximal end of the sleeve is adapted to be detachably attached to the distal end of the protrusion for the second face plate after the first face plate and second face plate have been pivoted back together and aligned 
     In another embodiment the first face plate has a first gasket attached to an opposite side of the first face plate from the first protrusion and the second face plate has a second gasket attached to an opposite side of the second face plate from the second protrusion. These gaskets serve to help provide an air-tight seal of the cover against the opening in the structure where the line sets exit, thereby further protection. 
     The invention provides for the closure of the face plates around the line sets to be protected and the sleeve is then wrapped around the line sets to form a cone shaped protection defined by the hollow cone protrusion and the continuing sleeve. The sleeve includes securing means to keep the sleeve tight around the shielded line sets. If the cover needs to be removed for serving of the line sets, the clover is undone in the reverse manner. 
     Other and further objects, features, and advantages of the present invention will be apparent from the following description of the present invention, given for the purpose of disclosure, and taken in conjunction with the accompanying drawings. It is to be understood that the following detailed description and the accompanying drawings are not to be taken in a limiting sense. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is an elevation view of the present invention assembled. 
         FIG.  2    is a frontal perspective view of the present invention during installation. 
         FIG.  3    is a rear view of the perspective view of the present invention as shown in  FIG.  2   . 
         FIG.  4    is another frontal perspective view of the present invention during installation. 
         FIG.  5    is a perspective view of the present invention assembled. 
         FIG.  6    is a side view of the present invention assembled. 
         FIG.  7    is a rear view of the present invention assembled. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present disclosure describes an HVAC line set cover in accordance with certain embodiments of the present invention. Characteristics and advantages of the present disclosure and additional features and benefits will be readily apparent to those skilled in the art upon consideration of the following detailed description of exemplary embodiments of the present disclosure and referring to the accompanying figures. It should be understood that the description herein and appended drawings, being of example embodiments, are not intended to limit the claims of this patent or any patent or patent application claiming priority hereto. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the claims. Changes may be made to the particular embodiments and details disclosed herein without departing from such spirit and scope. 
     In showing and describing preferred embodiments in the appended figures, common or similar elements are referenced with like or identical reference numerals or are apparent from the figures and/or the description herein. The figures are not necessarily to scale, and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness. 
     As used herein and throughout various portions (and headings) of this patent application, the terms “disclosure”, “present disclosure” and variations thereof are not intended to mean every possible embodiment encompassed by this disclosure or any particular claim. Thus, the subject matter of each such reference should not be considered as necessary for, or part of, every embodiment hereof or of any particular claim merely because of such reference. 
     The term “coupled” and the like, and variations thereof, as used herein and in the appended claims are intended to mean either an indirect or direct connection or engagement. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices and connections. 
     Certain terms are used herein and in the appended claims to refer to particular components. As one skilled in the art will appreciate, different persons may refer to a component by different names. This document does not intend to distinguish between components that differ in name but not function. 
     Also, the terms “including,” “comprising,” “including,” and “having” are used herein and in the appended claims in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ” Further, reference herein and in the appended claims to components and aspects in a singular tense does not necessarily limit the present disclosure or appended claims to only one such component or aspect, but should be interpreted generally to mean one or more, as may be suitable and desirable in each particular instance. 
     Preferred embodiments of the present disclosure offer advantages over the prior art and are well adapted to carry out one or more of the objects of this disclosure. However, the present disclosure does not require each of the components and acts described above and are in no way limited to the above-described embodiments or methods of operation. Any one or more of the above components, features and processes may be employed in any suitable configuration without inclusion of other such components, features, and processes. Moreover, the present disclosure includes additional features, capabilities, functions, methods, uses, and applications that have not been specifically addressed herein but are, or will become, apparent from the description herein, the appended drawings, and claims. 
     The present technology now will be described more fully hereinafter with reference to the accompanying figures, in which some preferred embodiments of the invention are shown. This technology may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. 
     Referring to  FIG.  1   , line set cover  1000  is attached to wall  10  of a structure and surrounds opening  20  in wall  10  which may be referred to as a perforation in wall  10  as well. HVAC line sets  30  and  40  extend through opening  20  and line set cover  1000 . 
     Referring now to  FIGS.  1  and  2   , line set cover  1000  is comprised of first face plate  100 , second face plate  200 , first hollow cone shaped protrusion  150 , and hollow cone shaped protrusion  250 . Protrusion  150  has a proximal end  154  and a distal end  155 . Protrusion  250  has a proximal end  254  and a distal end  255 . Line set cover  1000  further comprises a sleeve  400  having a proximal end  455  and a distal end  465 . As used herein, a cone shall mean any shape that serves to provide an extension from the opening  20  in wall  10  and shall include other hollow shapes such as a cylinder, rectangle, a multi-sided prism, or a multi-sided pyramid frustrum. 
     Sleeve  400  includes a first edge  491  and a second edge  493 . Once installed as described below, first edge  491  forms the proximal end  455  of sleeve  400  and second edge  493  forms the distal end  465  of sleeve  400 . As shown in  FIG.  2   , proximal end  455  of sleeve  400  is adapted to be coupled to distal ends  155  and  255  of protrusions  150  and  250 , respectively, as described further below. 
     Referring still to  FIG.  2   , line set cover  1000  is shown during the installation before first face plate  100  and second face plate are attached to wall  10  of the structure. As shown in detail in  FIG.  2   , plates  100  and  200  are rotatably pivoted apart about pivot point  300 . In this installation configuration, first protrusion  150  of plate  100  and the second protrusion  250  of plate  200  are rotatably pivoted about pivot point  300  and are shown at about a 90-degree rotation relative to one another. 
     Referring now to  FIGS.  2  and  3   , protrusion  150  extends outwardly from face plate  100  into the outside environment toward the outside HVAC air compressor. Similarly, protrusion  250  extends outwardly from face plate  200  into the outside environment toward the outside HVAC air compressor. In at least one embodiment, first face plate  100  and its protrusion  150  and second face plate  200  and its protrusion  250  may each be formed as a single integrated plastic unit using injection molding, for example. In one preferred embodiment the plastic is acrylonitrile styrene acrylate (ASA), and the thickness of the plastic is between 0.05 inches and 0.3 inches. Other potential plastics are ABS, PVC, polypropylene, and polycarbonate. 
     Referring still to  FIGS.  2  and  3   , a portion of distal end  155  of protrusion  150  is preferably non-detachably attached, or fixed, to a portion of sleeve  400  near edge  491  at the proximal end  455  of sleeve  400 . Sleeve  400  can be made of any number of elastomers such as rubber, soft PVC and LDPE. In at least one embodiment, sleeve  400  is made of SANTOPRENE® available from Celanese Corporation. Sleeve  400  may also be manufactured by injection molding. 
     In at least one embodiment, at least a portion of edge  491  at proximal end  455  of sleeve  400  is attached to the distal end  155  of protrusion  150  by molding end  455  over distal end  155 , known as over-molding. Sleeve  400  may be referred to as a sleeve membrane herein. Sleeve  400  may also be referred to as an elastomeric sleeve herein. As shown in  FIG.  2   , all of proximal end  485  formed along first edge  491  edge of sleeve  400  is not permanently attached to distal end  255  of protrusion  250 . This allows second plate  200  to be rotated about point  300  and engage first protrusion  150 . Then sleeve  400  may be wrapped around line sets  30 / 40  at edge  491  and attached to the distal end  255  of protrusion  250  as sleeve  400  as described in further detail below. Point  300  may be a manufactured part of the cover as shown in  FIG.  4   . It is shown as comprising a pin with half key that can be inserted in the opening of  300  on face plate  100  and then rotated to lock when the face plate  100 / 200  are aligned after placing over the line sets. Alternatively, a bolt, washer, nut type fastener (not shown) may pass through pivot point  300  and serve as the pivoting connection. 
     Sleeve  400  includes detachable securing means that allows proximal end  485  of sleeve  400  to be detachably attached to distal end  255  of protrusion  250  as sleeve  400  is wrapped around line sets  30 / 34 . In at least one embodiment, proximal end  455  has channels  488  formed along first edge  490 . Matching ribs  258  are formed on the distal end  255  of protrusion  250 . Channels  488  and ribs  258  are sized so that channels  488  may be pressed over ribs  258  causing a friction fit. Additionally, protrusion  250  has guide pins  220  and protrusion  150  has guide cavities  120  so that when line set cover  1000  is placed around the line sets  30 / 40  and face plates  100  and  200  are pivoted about point  300  back into alignment, guide pins  220  fit into guide cavities  120  on protrusion  150  to ensure an accurate alignment. 
     Referring to  FIG.  3   , gasket  170  is attached to first plate  100  and second gasket  270  is attached to second plate  200 . Gaskets  170  and  270  serve to provide an airtight fit for cover  1000  against wall  10 . In at least one embodiment, gaskets  170  and  270  are made of PVC foam as commercially from Tianjin Dagu. First plate  100  includes apertures  110  and second plate  200  includes apertures  210 . Apertures  110  and  210  accommodate fasteners such as screws, bolts, etc. to attach line set cover  1000  to wall  10  once the installation is completed. Referring still to  FIG.  3   , protrusion  250  includes brace member  230  which slopes downwardly to help shape protrusion  250  and direct any water than has leaked into the cover  1000  downwardly away from wall  10 . 
     The installation of line set  1000  will now be described. First plate  100  is first rotated relative to second plate  200  about pivot point  300  as shown in  FIG.  2   . The installer then positions line set cover  1000  around line sets  30 / 40 . The second plate is then rotated about point  300  and guide pins  220  enter and lock within guide cavities  120 . 
     Referring now to  FIG.  4   , the next step is to wrap sleeve  400  around line sets  30 / 40 . This is accomplished by attaching the beginning of channels  488  at the proximal end  455  of sleeve  400  onto ribs  258  formed on the distal end  255  of protrusion  250 . Channels  488  are then pressure fitted completely around onto ribs  258 . To ensure sleeve  400  is tightly attached around line sets  30 / 40  as shown in  FIG.  1   , distal end  465  of sleeve  400  includes opening  495 . 
     As shown in  FIGS.  2  and  4   , a latch  165  is formed at the proximal end  455  of sleeve  400 . The opening  495  and latch  165  are positioned and sized so that opening  495  it fits latch  165  and secures sleeve  400  tightly around line sets  30 / 40 . Since sleeve  400  is preferable elastomeric and therefore stretchable, opening  495  can be stretched so that when opening  495  is placed over latch  165 , sleeve  400  is in tension and will not become unattached from distal end  155  of protrusion  250 . After tightly securing line sets  30 / 40  within sleeve  400 , fasteners may be inserted through openings  110 / 210  securing line set cover  1000  to wall  10 . When further repairs are required, this configuration also allows sleeve  400  to be detached from second protrusion  250  by pulling sleeve  400  consequently stretching opening  495  away from latch  165  and channels  488  may be peeled away from ribs  258 . 
       FIGS.  5  and  6    show an installed line set cover  1000  of the present invention. Face plates  100 / 200  are pivoted together and sleeve  400  is attached around line sets (not shown). Sleeve  400  may be cut to different lengths to accommodate different sizes and numbers of line sets. Sleeve  400  may also be tightened around line sets using various methods such as self-locking zip ties. To assist in cutting sleeve  400 , sleeve  400  in at least one embodiment may include score lines at the distal end  465  so that the installer may cut the opening of the wrapped-around sleeve  400  to the desired fit for the specific application. 
     In this manner, line set cover  1000  of the present invention can be easily installed and removed when a service person needs access to line sets, such as copper tubing, located within sleeve  400  or protrusions  150 / 250  for maintenance and repair. 
     This disclosure results in improved HVAC efficiency and allows for simple, fast, and more efficient installations. It also permits the installer to aesthetically cover the exiting line set from a structure. Thus, operating cost and installation costs are lower than with prior art line set covers. 
     The invention in its broader aspects is not limited to the specific details of the preferred embodiments shown and described, and it will be appreciated that variations and modifications can be made without departing from the scope of the invention.