Patent Publication Number: US-9845971-B1

Title: Stacking brackets and systems for rooftop HVAC units

Description:
TECHNICAL FIELD 
     The present invention relates to stacking of heating, ventilation, and air conditioning (HVAC) units and, more particularly, to packaging and stacking brackets for rooftop HVAC units and methods of making and using the same. 
     BACKGROUND 
     Heating, ventilation, and air conditioning (HVAC) units are used to condition air to make a controlled environment more pleasant. Often in commercial buildings, such as grocery stores, restaurants, and other stores, rooftop units are installed as self-contained units located on the rooftops. These rooftop units are stored as multi-unit stacks and have to be transported to the commercial building for installation. The transportation is typically accomplished using a semi-trailer truck. To use the space on the semi-trailer truck efficiently, two rooftop HVAC units are often stacked on top of each other, placed a flatbed trailer, and strapped in place. The stacking may poses certain risks of damage to the rooftop units. To avoid damage, wood crates have at times been used. 
     SUMMARY 
     According to an illustrative embodiment of the disclosure, a system for securing at least two heating, ventilation, and air conditioning (HVAC) units stacked on each other for transportation includes a first HVAC unit having a bottom frame formed with base rails. The first HVAC unit having four bottom corners on a bottom portion and a top planar surface forming four top corners on a top portion. The system further includes a second HVAC unit having a bottom frame formed with base rails and having four bottom corners on a bottom portion and a top planar surface forming four top corners on a top portion. The system further includes a first corner bracket, a second corner bracket, a third corner bracket, and a fourth corner bracket applied to each of the four top corners of the first HVAC unit. 
     The system also has a first lateral banding member extending laterally across the first HVAC unit going from a first longitudinal side of the first HVAC unit to a second longitudinal side of the first HVAC unit. The first lateral banding member extending over and held in place by the first and second corner brackets. The system also has a second lateral banding member extending laterally across the first HVAC unit going from a first longitudinal side of the first HVAC unit to a second longitudinal side of the first HVAC unit. The second lateral banding member extending over and held in place by the third and fourth corner brackets. 
     The system further includes a first plank member extending between and secured to the first corner bracket and the fourth corner bracket and positioned proximate a first longitudinal edge of the first HVAC unit. The system also has a second plank member extending between and secured to the second corner bracket and the third corner bracket and positioned proximate a second longitudinal edge of the first HVAC unit. Each of the first, second, third, and fourth corner brackets each are formed from a bracket body having at least one lateral banding channel and having a plank-receiving channel. 
     According to another illustrative embodiment of the disclosure, a corner bracket for placing on four corners of a first HVAC unit to assist with stacking a second HVAC unit on the first HVAC unit includes a bracket body formed from a synthetic material and formed with a plank-receiving channel. The bracket body is formed from a synthetic material and has a top side, an outer lateral side, an inner lateral side, an outer longitudinal side, and an inner longitudinal side with reference to an installed position. The bracket also includes a first top protrusion formed on the top side of the bracket body and extending vertically away from other portions of the bracket body on the top side to define a first height and positioned proximate an interface of the inner lateral side and the top side. The first top protrusion is for positioning a portion of a base rail of a bottom frame of the second HVAC unit and includes a banding channel formed laterally across the top side of the bracket body for receiving one or more bands. 
     The corner bracket further includes a second top protrusion formed on the top side of the bracket body and extending vertically away from other portions of the bracket body on the top side to define a second height. The second top protrusion displaced longitudinally from the first top protrusion to form a lateral, top strapping channel between the first top protrusion and the second top protrusion. The corner bracket also having a first outer longitudinal protrusion and a second out longitudinal protrusion formed on the bracket body and displaced from one another to form a longitudinal strapping channel for receiving a strap. The plank-receiving channel is sized and configured to receive the plank member. 
     According to an illustrative embodiment of the disclosure, a corner bracket for use on the top corners of HVAC units when stacked for transportation includes a bracket body formed from a synthetic material and formed with a longitudinal plank-receiving channel for receiving a plank extending longitudinally between longitudinally opposed corner brackets when in a deployed position with a corner bracket on each corner of the HVAC unit. The corner bracket includes a plurality of protrusions formed on a top surface of the bracket body for defining a first strapping channel. The first strapping channel is sized configured to receive a first trailer strap. The first trailer strap is held in relative position when deployed by the first strapping channel. The corner bracket also includes a lateral banding channel formed on the top surface of the bracket body for receiving banding member to hold the corner bracket in position. The corner bracket also includes a plurality of side protrusions for forming at least a second strapping channel. The second strapping channel is sized and configured to receive a second trailer strap that is held in relative position by the plurality of side protrusions that form the second strapping channel. Other embodiments are disclosed herein. 
    
    
     
       BRIEF DESCRIPTION 
       Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  is a schematic perspective view of part of an illustrative embodiment of a system for securing at least two heating, ventilation, and air-conditioning (HVAC) units; 
         FIG. 2  is a detail of a portion of the system of  FIG. 1 ; 
         FIG. 3  is a schematic, side elevational view of an HVAC unit showing banding deployed and in place for holding two corner brackets in place; 
         FIG. 4  is a schematic plan view of a portion of the system of  FIG. 1  showing two corner brackets and a plank; 
         FIG. 5  is a schematic elevation view of the two corner brackets and plank of  FIG. 3 ; 
         FIG. 6  is an end view of one of the corner brackets from  FIG. 4 ; 
         FIG. 7  is a schematic, perspective view of an illustrative embodiment of a corner bracket according to one illustrative embodiment; 
         FIG. 8  is a schematic elevation view of the corner bracket of  FIG. 6 ; 
         FIG. 9  is a schematic, cross-sectional view of the corner bracket of  FIG. 6  taken along a line running through the two fastener recesses on the top surface; and 
         FIG. 10  is a detail from  FIG. 8 . 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to the figures, and initially and primarily to  FIG. 1 , a portion of a system  100  for securing at least two heating, ventilation, and air-conditioning (HVAC) units stacked on each other for transportation is presented. A first HVAC unit  104  is shown, which is a roof-top HVAC unit having a bottom frame  108  formed with base rails  112  and having four bottom corners of which three  116 ,  120 , and  124  are visible. The first HVAC unit  104  includes a top planar surface  128  having top four corners  132 ,  134 ,  146 ,  140 . A first corner bracket  148  is shown positioned on top corner  132 . A second corner bracket  152  is shown positioned on the top corner  134 . A third corner bracket  156  is shown positioned on top corner  136 . Finally, a fourth corner bracket  160  is shown positioned on top corner  140 . 
     A second HVAC unit would be stacked on top of the first HVAC unit  104 . The second HVAC unit is analogous to the first HVAC unit  104 . For illustration purposes, only a bottom frame  164  of the second HVAC unit is shown on top of the first HVAC unit  104 . The bottom frame  164  of the second HVAC unit has four corners  168 ,  172 ,  176 , and  180  that are shown resting on the four corner brackets  148 ,  152 ,  156 , and  160 . In this view, the fourth corner  180  can be seen to the outboard of much of the fourth corner bracket  160 . 
     Referring now primarily to  FIG. 2 , the bottom frame  164  of a second HVAC unit is shown in more detail resting on the second corner bracket  152 . The bottom frame  164  includes bottom rails  166  that may be formed with a plurality of access openings  167  to accommodate banding and to provide visibility and other access. The bottom frame  164  may be coupled to sheet metal or other aspects of the second HVAC unit using fasteners going through a plurality of fastener holes  165 . Each bottom rail  166  has a bottom member  169  that forms a surface that rests upon the corner brackets, e.g., second corner bracket  152 . 
     Referring to  FIGS. 1 and 2 , a first plank member  184  is shown extending longitudinally between the first corner bracket  148  and the fourth corner bracket  160 . The first plank member  184  is positioned proximate a first longitudinal edge  186  of the first HVAC unit  104 . The second plank member  188  is shown extending longitudinally between the second corner bracket  152  and the third corner bracket  156 . The second plank member  188  is positioned proximate a second longitudinal edge  190  of the first HVAC unit  104 . As will be described further below, the plank members  184  and  188  extend within plank-receiving channels in their respective corner brackets. The plank members  184  and  188  may be made from wood, composite wood, high-density polyethylene, or other materials that are strong enough to distribute forces. In one illustrative embodiment, the planks  184 ,  188  were formed from 1″×4″ wood members, but 2×4″ or other dimensions and materials may readily be used. The planks  184 ,  188  may help keep the corner brackets from flexing inward and help to distribute loads outward to where there is more strength in the HVAC units. The planks may also tie the corner brackets together in the longitudinal direction. Screws are currently used as fasteners but a peg or other locking means could be used to tie together the planks and the brackets. 
     Referring primarily now primarily to  FIG. 3 , in this front elevation view, the second corner bracket  152  and third corner bracket  156  are shown in position on the top corners  172  and  176  respectively. In this view, a first lateral banding member  192  is shown going across a top portion of the second corner bracket  152  and looping through two of the access openings  167 . The first lateral banding member  192  thus extends laterally across the top of the first HVAC unit  104  going from a first longitudinal side (not shown in  FIG. 3 ) across the first corner bracket  148  (not shown in  FIG. 3 ) and the second corner bracket  152  down to a second longitudinal side  196  of the first HVAC unit  104 . As will be explained further below, a first lateral banding member  192  is held in place by banding channels. A second lateral banding member  200  extends laterally across the first HVAC unit  104  going from a first longitudinal side, across the top, to a second longitudinal side  196 . Again, as will be explained, lateral banding channels on the third corner bracket  156  and the fourth corner bracket  160  hold the banding member in place. 
     While not explicitly shown, the second HVAC unit is analogous to the first HVAC unit  104  and for a number of reasons may also have four corner brackets applied to its four top corners. These additional brackets—fifth, sixth, seventh, and eighth stacking brackets—are analogous to the other corner brackets and are positioned on the four top corners to accommodate banding of the two HVAC units together for stability and protection. Moreover, in some situations, three HVAC units may be stacked or other items placed on top. 
     Referring now to primarily  FIGS. 4-10 , an illustrative non-limiting embodiment of the stacking brackets will be presented. Referring initially to  FIG. 4 , a top schematic plan view of the second corner bracket  152  and third corner bracket  156  are shown with second plank member  188  between the corner brackets  152 ,  156 . In this embodiment, the second plank member  188  is shown with a notch  204  cut out of an inner longitudinal edge in order to accommodate a particular HVAC unit. In addition, an optional foam member  208  is shown extending beyond a periphery of the second plank member  188 . 
       FIG. 5  is a side elevation view of  FIG. 4 . For this illustrative embodiment, it will be appreciated that there are two fastener recesses  212  formed on a top portion of each bracket and two fastener recesses  216  formed on a side portion. The other side of the brackets may also have fastener recesses. Each of the fastener recesses  212 ,  216  allow for fasteners to extend through the corner bracket and into the plank member to help secure the plank member within a plank-receiving channel (see  228  in  FIGS. 7 and 9 ). This wall may also be used to pre-locate the assembled bracket and plank against the unit along its length so that the top locating features  252  are not considerably misaligned. 
     Continuing to refer to  FIGS. 4-10 , the second corner bracket  152  will be described in more detail. Those skilled in the art will appreciate that all of the brackets herein are analogous although some are mirror images of the others. The second corner bracket  152  is formed as a bracket body  224  from a synthetic material, such as polypropylene or recycled polypropylene. The bracket body  224  may take a number of shapes; for example, in one illustrative, non-limiting embodiment, the bracket body  224  is in the form of a cuboid shaped member with a plank-receiving channel  228 . The bracket body  224  is formed with the plank-receiving channel  228  as shown best in  FIG. 9 . 
     The plank-receiving channel  228  is sized and configured to receive the corresponding plank member. The plank-receiving channel  228  may take numerous shapes and in one embodiment may be a channel having an open side and in another embodiment may form a plank-receiving socket having a top wall, bottom wall, first side wall, second side wall, and an end wall. The bracket body  224  has a top side  232 , an outer lateral side  236 , an inner lateral side  240 , an outer longitudinal side  244 , and an inner longitudinal side  248 . It will be appreciated that the top side  232  has various features with different heights that may be referenced by an average height for all the surfaces from a datum. 
     In this regard, a first protrusion  252  is formed on the top side  232  of the bracket body  224  and extends vertically away from other portions of the bracket body  224  (e.g., from the average height for all the surfaces from a datum) to define a first height  256  ( FIG. 8 ). The first protrusion  252  is positioned proximate an interface, or edge, of the inner lateral side  240  and the top side  232 . The first protrusion  252  helps to position and maintain a portion of the base rail or the corner of the bottom frame  164  of the second HVAC unit as is shown on the fourth corner bracket  160  in  FIG. 1 . A lateral banding channel  260  is formed in the bracket body  224  by forming the channel  260  beneath other portions of the top surface or side  232  or by using one or more protrusions on each side, such as the first protrusion  252 . The banding channel  260  on each corner bracket provides a place to securely hold the banding member, e.g. banding members  192 ,  200 , and may recess the banding member to avoid abrasion. The banding channel  260  may be formed adjacent to the first protrusion  252  or to the other location on the top side  232 . 
     A second top protrusion  264  is formed on the bracket body  224  on the top side  232  and extends vertically away from other portions of the bracket body  224  on the top side  232  to define a second height  268  ( FIG. 8 ). The first height  256  and the second height  268  may be at least ¼ of an inch. The second top protrusion  264  is displaced longitudinally from the first top protrusion  252  to form a lateral, top strapping channel  272  between the first top protrusion  252  and the second top protrusion  264 . The second top protrusion  264  may act to give some redundancy for containing any units stacked on top if the primary larger protrusion  252  is damaged. 
     The bracket body  224  may also have a third top protrusion portion  318  shown best in  FIGS. 5 and 7  with a height less than the first height  256  and second height  268 . This third protrusion may assist with sufficient thickness for fasteners or may provide additional support area. 
     The bracket body  224  is also formed with a first outer longitudinal protrusion  276  and a second outer longitudinal protrusion  280 . The first outer longitudinal protrusion  276  and the second outer longitudinal protrusion  280  are displaced from one another to form a longitudinal strapping channel  284  for receiving a strap on a semi-trailer. 
     As shown best in  FIG. 7 , the bracket body  224  may also include a first outer lateral protrusion  288  and a second outer lateral protrusion  292  that are displaced from one another to form a lateral strapping channel  296 . As shown best in  FIGS. 5 and 6 , the strapping channels (longitudinal strapping channel  284  and lateral strapping channel  296 ) may have visual indicia  300  applied to provide instructions. In the example shown, the visual indicia  300  says “strap here,” but any helpful information may be added. In some embodiments, the visual indicia  300  may be made from a reflective material to assist forklift drivers in seeing it in warehouses and places where lighting is minimal. 
     As shown best in  FIG. 7 , an L-shaped rail-receiving area  320  may be formed as an aspect of the top side  232 . The L-shaped rail-receiving area  320  has a longitudinal portion  324  extending longitudinally and near the outer lateral side and has a lateral portion  328  extending laterally across the bracket on an outer longitudinal edge. The L-shaped rail-receiving area  320  is for receiving a corner of the bottom frame of an HVAC unit. In this embodiment, the bottom frame of the HVAC unit is received in the L-shaped rail-receiving area  320  outboard of the protrusions  252 ,  264 ,  318 . This can be seen, again, on the fourth corner bracket  160  in  FIG. 1 . In an alternative embodiment, the protrusions could be outboard of the area for receiving the bottom frame. 
     As shown best in  FIGS. 9 and 10 , in one illustrative, non-limiting embodiment, the plank member, e.g., second plank member  188 , is inserted into the corresponding plank-receiving channel, e.g., plank receiving channel  228 , until a longitudinal end of the plank member is against an internal wall  304  and then fasteners may be applied through the plurality of fastener recesses  212 ,  216 . As shown in  FIG. 10 , each of the fastener recesses  212  (or  216 ) may be formed with a protruding lip member  308  to counter wear or other issues from the fastener—particularly if sheet metal screws are used for the fastener. In other embodiments, the plank member may be held in place by an interference fit (snap-together design), glue, screws, or other fastening technique. 
     The corner bracket  152  may include a plurality of ridges  312  with a corresponding plurality of void spaces  316 . The plurality of void spaces  316  allow for less material to be used and makes the part more lightweight. The plurality of ridges  312  and void spaces  316  may be formed on both of the lateral sides or just one of the lateral sides. The ridges  312  and void spaces  316  may also be formed on the longitudinal side as shown in  FIG. 6 . 
     In use, first HVAC unit  104  may have four corner brackets  148 ,  152 ,  156 , and  160  applied to the top corners. Banding is then run laterally across the unit through the banding channels  260  and through one or more of the access openings  167  on each side of the lower frame member of the first HVAC unit. In this way, the corner brackets are securely attached to the first HVAC unit. Then, the second HVAC unit may be placed on top of the first HVAC unit  104  with the second bottom frame  164  resting on each of the corner brackets. Four more corner brackets, i.e., fifth, sixth, seventh, and eighth corner brackets, may be applied to the top corners of the second HVAC unit. A second banding member may be applied across the second HVAC unit. The banding member may run from either the access openings  167  on the bottom frame of the first HVAC member or some embodiments could be from the second bottom frame  164 . More typically, the banding would be from the bottom frame  108  of the first HVAC unit across the corner brackets on the second HVAC units at the top and then back down to the bottom frame  108  of the first HVAC unit and tightened to hold the whole unit securely in place. The banding need not go through the access openings or eyelets, but could go underneath the unit. 
     The unit may then be placed on a flat bed of a semi-trailer truck. Strapping members may then be run in two directions laterally and longitudinally. The lateral strapping may be held in place by the lateral strapping channel  296  and the longitudinal strapping may be held in place by the longitudinal strapping channel  284 . The process is reversed upon arrival at the commercial building and the corner brackets may be easily removed, and one may readily dispose of them. 
     The brackets and planks herein may perform multiple functions: protect the product from damage during stacking and unstacking, secure the product when multiple units are transported; protect the unit during shipment even when only one unit is being transported, or provide a location for strapping on flatbed trailers. 
     As used herein, the term “coupled” includes coupling via a separate object and includes direct coupling. The term “coupled” also encompasses two or more components that are continuous with one another by virtue of each of the components being formed from the same piece of material or associated one to another by a magnetic field. 
     The present invention and its advantages have been disclosed in the context of certain illustrative, non-limiting embodiments. The illustrative descriptions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Moreover, it should be understood that various changes, substitutions, permutations, and alterations can be made without departing from the scope of the invention as defined by the appended claims. It will be appreciated that any feature that is described in connection to any one embodiment may also be applicable to any other embodiment.