Patent Publication Number: US-2003221440-A1

Title: Kit for prolonging life of an air conditioning system

Description:
[0001] 1. FIELD OF THE INVENTION  
       [0002] The present invention relates generally to air conditioning systems, and, in particular, to a retrofitting kit and method for prolonging the lifetime of air conditioning systems through the use of an irrigation system whereby the condenser coils of the air conditioning system are sprayed with water.  
       [0003] 2. BACKGROUND OF THE INVENTION  
       [0004] Conventional air conditioning systems, such as those used for residential dwellings, typically share the following common features: evaporation coils, condenser coils, a compressor, and a fan for directing air flow across the condenser coils. The compressor acts as a pump and forces liquid refrigerant under pressure through the evaporation coils. Once the refrigerant enters the evaporation coils, its pressure is lowered along with its boiling temperature so that it becomes a vapor. During this change, the refrigerant absorbs heat from the warm air that is within the dwelling. The vaporized refrigerant must thereafter be removed to make room for additional liquid refrigerant. Rather than be released into the environment, this used refrigerant is recycled as follows: 1) vaporized refrigerant is pumped out of the evaporation coils and into the condenser coils; 2) while within the condenser coils, refrigerant is cooled by lower temperature air passing over the condenser coils; 3) once refrigerant is condensed to a liquid, the cycle begins again.  
       [0005] During those times in which the air conditioning system is used extensively, such as when the environmental air ambient temperatures are high, the condenser coils may become overheated causing the air conditioning system to either operate inefficiently or completely shut down. A well-known concept employed to reduce the workload on the air conditioner compressor is to spray water directly upon the condenser coils. Examples of this teaching are found in the following United States patents: Faxon U.S. Pat. No. 4,240,265 and Shires U.S. Pat. No. 4,274,266. Typically, these air conditioning condenser unit cooling apparatuses are either responsive to a particular temperature, whether it be ambient temperature or the temperature of the condenser coils, or they are responsive to the operation of the compressor. For example, Welker et al. U.S. Pat. No. 4,685,308, discloses a temperature responsive air conditioner cooling apparatus which sprays water over the air conditioner coils, whereas Scott U.S. Pat. No. 3,872,684 discloses an air conditioner condenser cooling device that delivers a spray mist to the condenser coils only while the compressor is operating.  
       [0006] While the prior apparatuses and devices are satisfactory for increasing the efficiency of an air conditioner, the fact that they are typically either solely temperature responsive or solely responsive to the compressor being in operation limits their effectiveness. Such devices have a tendency to spray the coils needlessly thereby causing a waste of water and potential damage to the surrounding environment. Just because the compressor is operating or because the ambient temperature is high does not mean that the air conditioner is being over worked. However, the fact that both the ambient temperature is high and the compressor is operating should give a good indication that the air conditioning system is being over worked and could use some help to operate more efficiently.  
       [0007] A further disadvantage of the prior air conditioning cooling apparatuses is that they can sometimes involve complex installation. Additionally, if the air conditioning system is fairly old and will likely need to be replaced sooner than later, the purchase of an expensive retrofitting device for prolonging the life of the air conditioning unit is not particularly desirable.  
       [0008] Accordingly, there remains a need for an inexpensive air conditioning system cooling apparatus that is responsive to both the operation of the compressor and the ambient temperature, that is easily installed, and that it will effectively reduce the condensing pressure of the air conditioner to normal conditions.  
       SUMMARY OF THE INVENTION  
       [0009] According to its major aspects and briefly recited, the present invention is a method and apparatus for prolonging the life of an air conditioning system by effectively reducing excessive condensing pressure. The apparatus is mounted onto a conventional air conditioner and includes a water valve that is connected on one end to a water source and on an opposing end to a means for spraying water directly on the condenser coils of the air conditioning unit. The water valve is operated by a controller that acts as a dual sensor for sensing whether a certain ambient temperature has been reached and whether the compressor is activated. The apparatus may be purchased as a backfit or retrofit kit and easily assembled by the average homeowner or technician withhout the use of special tools.  
       [0010] The present invention further includes method for prolonging the lifetime of air conditioning systems. The method includes the following steps: 1) mounting a controller housing that includes a controller and a water valve having an intake end and a discharge end onto a conventional air conditioner; 2) connecting the intake end of the water valve to a water source; 3) connecting the discharge end of the water valve to a means for spraying water; 4) placing the spraying means in close proximity to the condenser coils of the air conditioning unit; 5) operably connecting controller, which includes a temperature sensor and an compressor operation sensor, to the water valve; and 6) presetting the temperature sensor to a certain temperature. In operation, the water valve will be in an open position only when the ambient temperature reaches that of the preset temperature and when the compressor is in operation. If either the ambient temperature is below that of the preset temperature or if the compressor is not operating, then the water valve will be in the closed position and no water will be directed onto the condenser coils of the air conditioning unit.  
       [0011] A feature of the present invention is the use of an apparatus that can be purchased as a retrofitting kit for prolonging the life of an air conditioning unit. The kit includes such items as a water valve, a controller, a spraying means, and fittings for connecting each of the various items together and can be easily assembled by a homeowner or technician without the use of special tools or expertise. This kit is especially useful for older air conditioning units with excessive condensing pressure. Rather than having to immediately replace the unit, one can simply purchase a retrofitting kit and prolong the life of the unit. However, the kit may also be useful throughout the life of the air conditioning unit, especially during the months of particularly high temperatures.  
       [0012] Another feature of the present invention is the use of a controller that acts as a dual sensor for use in the operation of the water valve. Typically, air conditioning apparatuses and devices for spraying water onto condenser coils include a single sensor, such as a sensor for sensing the temperature of a condenser unit or the ambient temperature. The present invention includes a controller for sensing ambient temperature and for sensing whether the compressor is activated. Accordingly, the condenser coils are only sprayed with water when a certain ambient temperature has been reached and when the compressor is operating. This reduces the needless spraying of water during the times when the air conditioning unit is operating efficiently. Therefore, water is conserved and potential damage to the surrounding environment is reduced.  
       [0013] Yet another feature of the present invention is the use of a spraying means to spray water directly onto the condenser coils of a conventional air conditioning unit. As previously discussed, the use of water to cool the condenser coils is an effective way of reducing the load on the air conditioner during conditions of extensive use, such as extreme environmental heat. By reducing the condensing pressure and overall stress on the compressor, the air conditioning unit operates more efficiently and the overall life of the unit is prolonged.  
       [0014] These and other features and their advantages will be clear to those skilled in the art of air conditioning cooling apparatuses for condenser coils from a careful reading of the Detailed Description of the Preferred Embodiments, accompanied by the following drawings. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0015]FIG. 1 is a perspective view of an apparatus for cooling the condenser coils of an air conditioning unit according to a preferred embodiment of the present invention;  
     [0016]FIG. 2 is a perspective view of an apparatus for cooling the condenser coils of an air conditioning unit according to an alternative preferred embodiment of the present invention;  
     [0017]FIG. 3 is a front view of a controller of an apparatus for cooling the condenser coils of an air conditioning unit according to an alternative preferred embodiment of the present invention; and  
     [0018]FIG. 4 is a perspective view of the items included in a retrofitting kit for prolonging the life of an air conditioning unit according to an alternative preferred embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
     [0019] Referring now to the drawings, FIG. 1 illustrates an outside air conditioner  10  of a conventional home air conditioning system that is connected to a cooling apparatus  12  for prolonging the life of air conditioner  10 . As shown, air conditioner  10  generally comprises a housing  14  enclosing a condenser unit having condenser coils, a compressor, and a fan. A grill  16 , positioned on the top wall of housing  14 , overlies fan, and a side grill  18  surrounds the condenser unit.  
     [0020] Cooling apparatus  12  of the present invention includes a controller housing  20 , which is mounted on air conditioner  10  by conventional means such as screw fasteners. Controller housing  20  includes a cover  22  for easy access to the components found therein. Within controller housing  20  is a controller  42  and a water valve  24  (both shown in FIG. 3) having an intake end  26  and an opposing discharge end  28 . As best shown in FIG. 3, intake end  26  of water valve  24  is connected to a water source  32 , such as a tap water source, and discharge end  28  of water valve  24  is connected to a means for spraying water  34 .  
     [0021] Spraying means  34  of cooling apparatus  10  includes an irrigation tube  36  having a misting nozzle  38  for directing water onto the condenser coils of air conditioner  10 . Preferably, spraying means is placed in close proximity to side grill  18  of condenser unit. As further illustrated in FIG. 1, housing  20  has plural openings  30  to provide access for various connections. Openings  30  may also be used to drain any water that has potentially leaked from water valve  24 .  
     [0022] Although FIG. 1 shows spraying means  34  as being propped up by a stake  40 , other means of supporting spraying means  34  are contemplated by the present invention. For example, an alternative preferred embodiment illustrated in FIG. 2 depicts spraying means  34  as mounted directly onto side grill  18  of air conditioner. In this arrangement, spraying means  34  includes a pipe header  37  that is fitted to plural angled irrigation pipes  39  that are positioned is such a way as to direct water onto the condenser coils. Preferably, pipe header  37  is mounted onto side grill  18  by conventional means such as clips.  
     [0023] A particular feature of the present invention is the use the use of spraying means  34  to spray water directly onto the condenser coils of a conventional air conditioning unit. As previously discussed, the use of water to cool the condenser coils is an effective way of reducing the load on the air conditioner during conditions of extensive use, such as extreme environmental heat. By reducing the stress on the compressor, the air conditioning unit operates more efficiently and the overall life of the unit is prolonged.  
     [0024] The operation of water valve  24  is best illustrated in FIG. 3. As shown, water valve  24  is activated by controller  42 , which includes a temperature sensor  44  for sensing ambient temperature and a compressor operation sensor  48 . Water valve  24  is preferably a solenoid valve that is operably wired to both temperature sensor  44  and compressor operation sensor  48  of controller  42 . As further illustrated, compressor operation sensor  48  may simply include a power lead from the air conditioner terminal indicating that the compressor is activated. The electrical circuit is completed by further connecting temperature sensor  44  to compressor operation sensor  48 . In operation, water valve  24  will be in an open position so as to direct water to spraying means  34  only when the ambient temperature reaches that of the preset temperature and when the compressor is working. If either the ambient temperature is below that of the preset temperature or if the compressor is not operating, then water valve  24  will be in the closed position and no water will be directed onto the condenser coils of the air conditioner.  
     [0025] Another particular feature of the present invention is the use of controller  42  that acts as a dual sensor to operate water valve  24 . Cooling apparatuses and devices for spraying water onto condenser coils of air conditioners typically include a single sensor, such as a sensor for sensing either the temperature of a condenser unit or the ambient temperature. The present invention combines ambient temperature sensor  44  and compressor operation sensor  48 . Accordingly, the condenser coils are only sprayed with water when a certain ambient temperature has been reached and when the compressor is operating. This reduces the needless spraying of water during the times when the air conditioning unit is operating efficiently. Therefore, water is conserved and potential damage to the surrounding environment is reduced.  
     [0026] As previously discussed, cooling apparatus  12  of the present invention may be purchased as a retrofitting kit for prolonging the life of air conditioner  10 . As shown in FIG. 4, the kit may include the following features: 1) controller housing  20 ; 2) water valve  24 ; 3) a hose  50  for connecting water valve  24  to water source  32 ; 4) a filter  52  to be placed in cooperation with hose  50  for filtering out such materials that may cause deposits on air conditioner  10 ; 5) a needle valve  54  for regulating the flow of water; 6) fittings  56 , such as T-connectors, for assembling spraying means  34 ; 7) temperature sensor  44 ; 8) wires  58  for assembling controller  42 ; and 9) means for mounting spraying means such as clips  60 . The kit may also include such further items as a water bib connector, irrigation pipes  39 , spray nozzles, means for attaching controller  42  to housing  14  of air conditioner  10 , and instructions for assembling cooling apparatus  12 .  
     [0027] This retrofitting kit is especially useful for older air conditioning units. Rather than having to immediately replace air conditioner  10 , one can simply purchase a retrofitting kit and prolong the life of the unit. However, the kit may also be useful throughout the life of the air conditioning unit, especially during the months of particularly high temperatures.  
     [0028] Finally, those skilled cooling apparatuses for air conditioners will recognize that may substitutions and modifications can be made in the foregoing preferred embodiments without departing from the spirit and scope of the present invention.