Patent Publication Number: US-2012039727-A1

Title: Air Conditioning Unit for Rescue Shelter Units

Description:
The current application claims a priority to the U.S. Provisional Patent application Ser. No. 61/373,712 filed on Aug. 13, 2010. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to an air conditioning unit. More specifically, the present invention utilizes compressed gas for multiple pneumatic pistons to power an air conditioning unit designed for rescue shelters. 
     BRIEF DESCRIPTION OF THE PRIOR ART 
     The following is a list of prior art related to the present invention with a brief description of the present invention&#39;s differences in comparison: 
     In the U.S. Pat. No. 5,139,392 is a refrigerant pump which uses a swash plate as the mechanism for compressing the refrigerant. The method of driving the shaft is not mentioned. The present invention uses pneumatically driven pistons connected to a swash plate to deliver the rotation needed to drive an A/C unit. 
     In the U.S. Pat. No. 5,809,863 is a swash plate type axial piston pump. However, this patent is for a single axial piston pump, whereas the present invention utilizes a compressed gas powered swash plate axial piston motor to power an A/C unit. 
     In the U.S. Pat. No. 5,009,574 is a swash plate designed compressor. The utilization of the swash plate in this patent is different from the present invention. The present invention utilizes a swash plate to rotate and drive a shaft to power the A/C unit. The compressor of the present invention is driven by the rotating shaft. 
     In the U.S. Pat. No. 5,145,325 is a swash plate designed compressor. The utilization of the swash plate in this patent is different from the present invention. The present invention utilizes a swash plate to rotate and drive a shaft to power the A/C unit. The compressor of the present invention is driven by the rotating shaft. 
     In the European Patent EP 1384886 is a piston designed for used in a compressor. The piston is primarily used for a swash plate carbon dioxide compressor. The utilization of the swash plate in this patent is different from the present invention. The present invention utilizes a swash plate to rotate and drive a shaft to power the A/C unit. The compressor of the present invention is driven by the rotating shaft. 
     In the U.S. Pat. No. 4,790,727 is a compressor that is used for an A/C unit specifically. The compressor in this patent still compresses the refrigerant. However, the design of the present invention provides the rotation for a generic air conditioning unit. 
     In the U.S. Pat. Nos. 3,999,893, 4,781,539, and the European patent EP0569958 is a similar invention to the U.S. Pat. No. 4,790,727 mentioned above. These patents introduce a swash plate as means of compressing the refrigerant. The present invention utilizes a swash plate to power a conventional compressor. 
     In the U.S. Pat. No. 5,694,784 is a similar system as the above mentioned systems in that it uses a swash plate to compress the refrigerants. However, it is different in that the refrigerant is carbon dioxide. The present invention does not use a swash plate for the compressor, nor is carbon dioxide used as the refrigerant. Oxygen is used as the gas to power the pneumatic pistons, which connected to the swash rotate a shaft that powers an A/C unit. 
     BACKGROUND OF THE INVENTION 
     During a mine collapse, the working miners are required to evacuate to a mine shelter for safety. The mine shelters often provide the structural support to provide the miners a safe space to stay until rescue arrives. The mine shelters often provide the miners with the necessities for survival including carbon dioxide scrubber systems, oxygen supply, rations, and other items required for survival. However, an unaddressed and considerable problem with current mine shelters during rescue operations of mines is heat. In extreme conditions, the temperatures within a mine shelter can reach dangerous levels. The present invention is able to bring the high level temperatures in the mine rescue shelters to provide the miners with a more comfortable environment. The present invention utilizes a series of pneumatic pistons to power a swash plate and shoe. The piston&#39;s linear motions are converted into a rotational motion by the swash plate and shoe. A shaft receives the rotational energy to rotate fans and an air conditioning compressor. The fans are able to circulate air within the shelter through a heat exchanger. The heat exchanger is able to draw the heat from the shelter and transfer it to an exterior heat exchanger to be dispelled. The present invention is a safe and simple solution that provides high flow rates of conditioned air. The gas used to pressurize the pistons is the O2 gas supplied to sustain the miners until rescue. The usage of the compressed gas and multiple pistons provides the power needed to fully power an air conditioning unit. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of the entire apparatus of the present invention. 
         FIG. 2  is an exploded view of the valve system, swash plate, swash plate shoe, plurality of pistons and the piston mount. 
         FIG. 3  is a left side elevational view of the valve system in which a sectional view is taken and shown in  FIG. 4 . 
         FIG. 4  is a bottom plan view of the cross section of the valve system showing a single spring valve being pushed out by the cam. 
     
    
    
     DETAIL DESCRIPTIONS OF THE INVENTION 
     All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention. 
     The present invention is an air conditioning unit designed specifically for, but is not limited to, mine rescue operations. The present invention is designed to be powered by the use of a compressed gas. The present invention comprises a unit frame  1 , a compressor  2 , a valve system  3 , a swash plate  4 , a swash plate shoe  5 , a plurality of pistons  6 , a fan unit  7 , an internal heat exchanger  8 , an external heat exchanger  9 , a plurality of gas tubes  10 , a plurality of spring valves  20 , and a belt  30 . The present invention utilizes the plurality of pistons  6  to provide the required force for powering the air conditioning unit of the present invention. The linear motion of the plurality of pistons  6  is converted into rotational motion. The rotational motion is then used for the powering of the air conditioning unit. 
     In reference to  FIG. 1 , the unit frame  1  is the structural body of the present invention that is able to hold and mount the other components of the present invention. The unit frame  1  comprises an internal heat exchanger rack  11 , an internal fan support  12 , an external heat exchanger rack  13 , an external fan support  14 , a drive train rack  15 , a compressor support  16 , and piston plate  17 . The drive train rack  15  is a pair of parallel bar supports that is held together by the compressor support  16  and the piston plate  17 . The internal heat exchanger rack  11  is a platform that is perpendicularly extended from one end of the drive train rack  15 . The external heat exchanger rack  13 , similar to the internal heat exchanger rack  11 , is perpendicularly extended from the drive train rack  15  in parallel relationship to the internal heat exchanger rack  11 . The external heat exchanger rack  13  is extended from the end of the drive train rack  15  opposite of the internal heat exchanger rack  11 . The internal fan support  12  is upwardly extended from the upper surface of the internal heat exchanger rack  11 . In a similar fashion, the external fan support  14  is upwardly extended from the upper surface of the external heat exchanger rack  13 . The compressor support  16  is connected across and is upwardly extended from the drive train rack  15 . The piston plate  17  is positioned on one end of the drive train rack  15 . The piston plate  17  is connected across and is positioned in parallel relationship to the compressor support  16 . 
     In reference to  FIG. 1 , the compressor  2  is an axial compressor that utilizes rotational forces to drive a refrigerant through the entire system. The compressor  2  comprises a compressor axle  21  and a compressor pulley  22 . The compressor axle  21  is extended concentrically from the compressor  2 . The compressor  2  is able to harness energy received through the compressor axle  21  to propel the refrigerant through the entire air conditioning system. The compressor pulley  22  is connected to the compressor axle  21  in concentric relationship. As the present invention solely relies on rotational energy generated by compressed gasses and the plurality of pistons  6 , the compressor pulley  22  provides the compressor  2  with the ability to share the rotational energy with other components. 
     In reference to  FIG. 1  and  FIG. 4 , the valve system  3  works in unison with the plurality of pistons  6 , the swash plate  4 , and the swash plate shoe  5  to generate the require rotational energy to power the present invention. The plurality of pistons  6  generate the required linear forces that are to be converted into the rotational motions by the swash plate  4 . The valve system  3  is able to regulate and distribute compressed gasses in series to the appropriate pistons for efficient generation of rotational forces. The valve system  3  comprises a first body plate  31 , a second body plate  32 , a plurality of valve channels  33 , a cam  34 , and a shoe mount  35 . The first body plate  31  comprises a plurality of first valve grooves  311 , a first hole  312 , and a plurality of exhaust holes  313 . The second body plate  32  comprises a plurality of second valve grooves  321 , a second axle  73  hole, and a plurality of inlet holes  323 . The first body plate  31  is secured to the second body plate  32  to create the body of the valve system  3 . The combination of the first body plate  31  and the second body plate  32  allows the first valve grooves  311  and the second valve grooves  321  to define the plurality of valve channels  33 . The plurality of exhaust holes  313  is holes that traverse through the first body plate  31  into the plurality of valve channels  33 . Similarly, the plurality of inlet holes  323  is holes that traverse through the second body plate  32  into the plurality of valve channels  33 . The first hole  312  is a hole that traverses through the center of the first body plate  31 . The second hole  322  is a hole that traverses through the center of the second body plate  32 . The first hole  312  and the second hole  322  are aligned and similarly sized to allow the cam  34  to be positioned through. The shoe mount  35  is positioned on the face of the second body plate  32  opposite of the first body plate  31  in concentric relationship with the second hole  322 . The cam  34  is concentrically connected to the compressor axle  21 . The compressor axle  21  traverses through the first hole  312  and the second hole  322  to be connected to the shoe mount  35 . The plurality of spring valves  20  is positioned in the plurality of valve channels  33  to control flow of the compressed gases moving through the system. 
     The swash plate shoe  5  is mounted onto the shoe mount  35  for to transfer rotational energy to the compressor axle  21 . The swash plate shoe  5  comprises a plate mount  51  and a mount socket  52 . The plate mount  51  is connecting component that allow the swash plate  4  to be connected to the swash plate shoe  5 . The plate mount  51  is positioned on an angled end of the swash plate shoe  5 . The mount socket  52  is positioned on the swash plate shoe  5  opposite of the angled end. The swash plate shoe  5  is mounted onto the shoe mount  35  by means of the mount socket  52 . The swash plate  4  comprises a plurality of plates  41  and a plurality of piston bearing sockets  42 . Each of the plates has a plurality of holes consistent with the number of pistons. The plurality of plate are aligned and secured to each other with the plurality of holes defining the piston bearing sockets. The combination of the plurality of holes creates a spherical socket for the connection to the plurality of pistons  6 . 
     In reference to  FIG. 2 , the each of the pistons of the plurality of pistons  6  comprises a cylinder chamber  61  and a piston arm  62 . The plurality of pistons  6  is connected to the plurality of piston bearing sockets  42  by means of the piston arms  62  to create a low friction interface. Each piston arm  62  comprises a plate bearing  63 . The plate bearings  63  are ball bearing ends on the piston arm  62  that fit directly into the plurality of piston bearing sockets  42 . The ball bearing ends of the piston arm  62  provides the plurality of pistons  6  with the ability to constantly provide the linear motion at differing angles to the swash plate. The plurality of piston bearing sockets  42  is evenly distributed on the swash plate  4  in a circular arrangement. As a result, the plurality of pistons  6  is correspondingly arranged in a circular fashion onto the swash plate  4 . It is important for this connection to be a low friction interface to ensure no energy is lost to heat and that all energy received by the compressed gas is translated into the rotational energy needed for the operation of the present invention. 
     In reference to  FIG. 1 , all the components are secured onto the unit frame  1  for proper operation. The compressor  2  is mounted and secured onto the compressor support  16  with the compressor axle  21  being extended towards the piston plate  17 . The valve system  3  is longitudinally secured onto the drive train rack  15  in parallel relationship to the compressor support  16 . The piston plate  17 , similar to the valve system  3 , is longitudinally secured to the drive train rack  15  in parallel relationship to the valve system  3 . The piston plate  17  additionally comprises of piston mounts  171 . The positioning and arrangement of the piston plate  17  allows the plurality of pistons  6  to be arranged in parallel relationship to the swash plate shoe  5 . The pistons are additionally secured to the piston plate  17  to their corresponding piston mounts  171 . The cylinder chamber  61 s are secured to the piston mounts  171  to provide the plurality of pistons  6  with the ability to move laterally. This positioning allows for optimal conversion of the linear force provided by the pistons to rotational force through the swash plate  4  and swash plate shoe  5 . 
     The internal heat exchanger  8  is secured onto the internal heat exchanger rack  11  in a vertical position. Similarly, the external heat exchanger  9  is secured onto the external heat exchanger rack  13  in a vertical position. The internal heat exchanger  8  and the external heat exchanger  9  are flat heat exchangers that are positioned so that the larger surfaces areas are perpendicular to the face of the internal heat exchanger rack  11  and the external heat exchanger rack  13 . This type of arrangement allows the grill fins of both heat exchangers to be directed towards the sides of the present invention. As a result, the internal heat exchanger  8  and the external heat exchanger  9  are able to efficient exchange heat with the environment. To increase the efficiency of heat exchange between the internal heat exchanger  8  and the external heat exchanger  9 , the fan unit  7  is used. The fan unit  7  comprises an internal fan  71 , an external fan  72 , a fan axle  73 , and a fan pulley  74 . The internal fan  71  is positioned on a first end of the axle  73  and the external fan  72  is positioned on the axle  73  opposite of the internal fan  71 . The fan unit  7  is able to receive rotational energy to power the fans by means of the fan pulley  74 . The fan pulley  74  is concentrically connected to the axle  73 . The belt  30  is looped about the fan pulley  74  and the compressor pulley  22  to allow the sharing of the rotational energy created by the valve system  3 , the swash plate  4 , the swash plate shoe  5 , and the plurality of pistons  6 . The axle  73  is secured to the internal fan support  12  and the external fan support  14 . As a result, the internal fan  71  is positioned adjacent to the internal heat exchanger  8  and the external fan  72  is positioned adjacent to the external heat exchanger  9  to create air flow through each corresponding heat exchanger. The internal heat exchanger  8  and the external heat exchanger  9  are both connected in line with the compressor  2 , as well as to each other to complete the refrigerant cycling loop. 
     In reference to  FIG. 1 , to operate the present invention, the valve system  3  is required to be connected to a compressed gas tank. The compressed gas tank is connected directly to the plurality of inlet holes  323  on the first body plate  31 . The plurality of valve channels  33  is connected to the cylinder chambers  61  of the plurality of pistons  6  by means of the gas tubes  10 . Each valve channel is connected to each cylinder chamber  61  to allow each individual piston to act independently. In the preferred embodiment of the present invention, the compressed gas used is oxygen. To control the flow of the compressed gas, the plurality of spring valve within the plurality of valve channels  33  further comprises of an inlet channel  201  and an exhaust channel  202 . Each of the spring valves  20  are normally closed and pushed towards the center of the valve system  3 . Given that the cam  34  is pressing a first spring valve out, an inlet channel  201  is aligned with the corresponding inlet hole. The compressed gas is able to through inlet channel  201  into the corresponding gas tube into the cylinder chamber  61  of the corresponding piston. The compressed gas builds pressure within the cylinder chamber  61  of the piston forcing the piston arm  62  to extend. The linear force from the piston arm  62  is translated to the swash plate  4 . The force applied to the swash plate  4  and the angled end of the swash plate shoe  5 , causes the swash plate shoe  5  to rotate. The degree of the angled end is able to determine the amount of force from the pistons that is required for the translation into rotational force or torque. The rotation of the swash plate shoe  5  causes the rotation of the cam  34  and the compressor axle  21 . This rotational energy is used to power the compressor  2  as well as the fan unit  7 . The fan unit  7  is able to receive the rotational energy through the compressor pulley  22 , the belt  30 , and the fan pulley  74 . The rotation of the cam  34  results in the release of the first spring valve. As the first spring valve is being released, the exhaust channel  202  will momentarily align with the exhaust hole. The pressure built up in the cylinder chamber  61  is released through the corresponding valve channel, through the exhaust channel  202  and out the exhaust hole. The rotation of the swash plate shoe  5  will continue and move the cam  34  to the next spring valve. The process will repeat continuously until the compressed gas supply has been depleted or if the system is shut off. Within a rescue shelter of a mine, the preferred compressed gas is oxygen. The design of the present invention allows the compressed gas to be released into the air of the rescue shelter for breathing as its compressed energy is utilized to power the unit. 
     As an example, the following is a description of one revolution of the swash plate  4  with four pistons. A first piston is at half through its throw and has ambient air filled inside its cylinder chamber  61 . A second piston is at full extension with the compressed gas filled into its cylinder chamber  61 . A third piston is at half through its throw similar to the first piston. A fourth piston is completely depressed. The cam  34  pushes open a spring valve which pressurizes the first piston. The piston pushes against the swash plate  4  which is attached to the swash plate shoe  5 . The movement of the swash plate shoe  5  also changes the position of the second, third, and fourth piston. The second piston is now at the halfway position of its displacement, the third piston at its zero displacement, and the fourth piston also being at the half way position of its displacement. The spring valve associated with the first piston is aligned so that the exhaust channel  202  is aligned with the exhaust hole to release the pressurized gas. At the same time, the spring valve associated with the second piston is aligned so that the inlet channel  201  is aligned with the inlet hole for the pressurization of the second piston. This pressure will force the second piston to complete displacement and will turn the swash plate  4  another 90 degrees. This process is continued until the present invention is turned off or the supply of gas is exhausted. 
     The torque or rotational force produced from the rotation of the swash plate shoe  5  is transferred to the compressor axle  21 . The compressor axle  21  may pass through a series of speed increasing gears and even a free wheel clutch. The compressor axle  21  will in turn run to the compressor  2  and the fan unit  7  using the belt  30  and the pulleys. 
     In reference to  FIG. 1 , an embodiment of the present invention shown is shown with four pistons, four and four valve channels  33 . This design allows for a low flow rate of gas at 10 liters/min or less to be translated into high rotational torque. In other embodiments of the present invention, there may be more pistons and valve channels  33  for a smoother rotational transition. However, there must be a minimum of three pistons positioned at even intervals around the swash plate  4  and the swash plate shoe  5  for continuous rotation. 
     Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.