Patent Publication Number: US-11047594-B2

Title: Air conditioning appliance and telescoping air plenum

Description:
FIELD OF THE INVENTION 
     The present subject matter relates generally to air conditioning appliances, and more particularly to air plenums for air conditioning appliances. 
     BACKGROUND OF THE INVENTION 
     Air conditioner or air conditioning appliance units are conventionally utilized to adjust the temperature within structures such as dwellings and office buildings. In particular, one-unit type room air conditioner units, such as single-package vertical units (SPVU), or package terminal air conditioners (PTAC) may be utilized to adjust the temperature in, for example, a single room or group of rooms of a structure. A typical one-unit type air conditioner or air conditioning appliance includes an indoor portion and an outdoor portion. The indoor portion generally communicates (e.g., exchanges air) with the area within a building, and the outdoor portion generally communicates (e.g., exchanges air) with the area outside a building. Accordingly, the air conditioner unit generally extends through, for example, an outer wall of the structure. Generally, a fan may be operable to rotate to motivate air through the indoor portion. Another fan may be operable to rotate to motivate air through the outdoor portion. A sealed cooling system including a compressor is generally housed within the air conditioner unit to treat (e.g., cool or heat) air as it is circulated through, for example, the indoor portion of the air conditioner unit. One or more control boards are typically provided to direct the operation of various elements of the particular air conditioner unit. 
     Some conventional air conditioning appliances include a plenum for directing air to or from an outdoor portion of the air conditioning appliance. When installed, the plenum may be positioned through a wall of the building or structure. The wall may be an outer wall such that the plenum extends from an interior portion of the building to an exterior portion of the building. Thus, a portion of the plenum will often extend to and be visible from an area outside of the building. However, is generally preferable (e.g., for aesthetics, support, sizing, performance, etc.) to minimize the amount of plenum exposed to the exterior environment. 
     The lack of standard wall sizes (e.g., thickness) makes sizing plenums difficult. Although multi-piece plenums sizes have been attempted to accommodate a range of wall, these structures present several drawbacks. For instance, an outer piece of such plenums typically includes a flange to rest against an external surface of the structure wall. Installers are thus forced to adjust and mount the plenum from outside of the building. This can be especially problematic in multi-story buildings, since an installer must use a ladder or elevated surface, which raises the danger of falling or being injured. 
     As a result, further improvements to air conditioners may be advantageous. In particular, it would be useful to provide a multi-piece plenum capable of being installed without inserting a piece from the outside of a building or structure. 
     BRIEF DESCRIPTION OF THE INVENTION 
     Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention. 
     In one exemplary aspect of the present disclosure, a telescoping plenum for an air conditioning appliance is provided. The telescoping plenum may include an interior portion and an exterior portion. The interior portion may include a duct wall and an outer flange extending radially outward from the duct wall to contact an internal surface of a structure wall. The exterior portion may include a duct wall having a flange-less outer surface to selectively pass through the wall channel along an axial direction. The exterior portion may be in slidable engagement with the interior portion to move along the axial direction. 
     In another exemplary aspect of the present disclosure, a single-package air conditioner unit is provided. The single-package air conditioner unit may include a housing, an outdoor heat exchanger assembly, an indoor heat exchanger assembly, a compressor, and a telescoping plenum. The housing may define an outdoor portion and an indoor portion. The outdoor heat exchanger assembly may be disposed in the outdoor portion and include an outdoor heat exchanger and an outdoor fan. The indoor heat exchanger assembly may be disposed in the indoor portion and comprising an indoor heat exchanger and an indoor fan. The compressor may be in fluid communication with the outdoor heat exchanger and the indoor heat exchanger to circulate a refrigerant between the outdoor heat exchanger and the indoor heat exchanger. The telescoping plenum may be attached to the housing and receivable within a wall channel defined by a structure wall along an axial direction. The telescoping plenum may include an interior portion and an exterior portion. The interior portion may include a duct wall and an outer flange extending radially outward from the duct wall to contact an internal surface of the structure wall. The exterior portion may include a duct wall having a flange-less outer surface to selectively pass through the wall channel along the axial direction. The exterior portion may be in slidable engagement with the interior portion to move along the axial direction. 
     These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures. 
         FIG. 1  provides a perspective view of an air conditioning appliance according to exemplary embodiments of the present disclosure. 
         FIG. 2  provides a partially-transparent elevation view of the exemplary air conditioner unit of  FIG. 1 . 
         FIG. 3  provides a perspective view of a plenum of an air conditioning appliance according to exemplary embodiments of the present disclosure. 
         FIG. 4  provides a schematic, sectional view of the exemplary plenum of  FIG. 3 , taken along the lines  4 - 4 . 
         FIG. 5  provides a schematic, sectional view of the exemplary plenum of  FIG. 3 , taken along the lines  5 - 5 . 
     
    
    
     DETAILED DESCRIPTION 
     Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. 
     As used herein, the terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). The terms “upstream” and “downstream” refer to the relative flow direction with respect to fluid flow in a fluid pathway. For example, “upstream” refers to the flow direction from which the fluid flows, and “downstream” refers to the flow direction to which the fluid flows. 
     Turning now to the figures,  FIGS. 1 and 2  illustrate an exemplary air conditioner appliance (e.g., air conditioner  100 ). As shown, air conditioner  100  may be provided as a one-unit type air conditioner  100 , such as a single-package vertical unit. Air conditioner  100  includes a package housing  114  supporting an indoor portion  112  and an outdoor portion  110 . 
     Generally, air conditioner  100  defines a vertical direction V, lateral direction L, and transverse direction T. Each direction V, L, T is perpendicular to each other, such that an orthogonal coordinate system is generally defined. 
     In some embodiments, housing  114  contains various other components of the air conditioner  100 . Housing  114  may include, for example, a rear opening  116  (e.g., with or without a grill or grate thereacross) and a front opening  118  (e.g., with or without a grill or grate thereacross) may be spaced apart from each other along the transverse direction T. The rear opening  116  may be part of the outdoor portion  110 , while the front opening  118  is part of the indoor portion  112 . Components of the outdoor portion  110 , such as an outdoor heat exchanger  120 , outdoor fan  124 , and compressor  126  may be enclosed within housing  114  between front opening  118  and rear opening  116 . In certain embodiments, one or more components of outdoor portion  110  are mounted on a basepan  136 , as shown. 
     During certain operations, air may be drawn to outdoor portion  110  through rear opening  116 . Specifically, an outdoor inlet  128  defined through housing  114  may receive outdoor air motivated by outdoor fan  124 . Within housing  114 , the received outdoor air may be motivated through or across outdoor fan  124 . Moreover, at least a portion of the outdoor air may be motivated through or across outdoor heat exchanger  120  before exiting the rear opening  116  at an outdoor outlet  130 . It is noted that although outdoor inlet  128  is illustrated as being defined above outdoor outlet  130 , alternative embodiments may reverse this relative orientation (e.g., such that outdoor inlet  128  is defined below outdoor outlet  130 ) or provide outdoor inlet  128  beside outdoor outlet  130  in a side-by-side orientation, or another suitable discrete orientation. 
     As shown, indoor portion  112  may include an indoor heat exchanger  122 , a blower fan  142 , and a heating unit  132 . These components may, for example, be housed behind the front opening  118 . A bulkhead  134  may generally support or house various other components or portions thereof of the indoor portion  112 , such as the blower fan  142 . Bulkhead  134  may generally separate and define the indoor portion  112  and outdoor portion  110  within housing  114 . Additionally or alternatively, bulkhead  134  or indoor heat exchanger  122  may be mounted on basepan  136  (e.g., at a higher vertical position than outdoor heat exchanger  120 ), as shown. 
     During certain operations, air may be drawn to indoor portion  112  through front opening  118 . Specifically, an indoor inlet  138  defined through housing  114  may receive indoor air motivated by blower fan  142 . At least a portion of the indoor air may be motivated through or across indoor heat exchanger  122  (e.g., before passing to bulkhead  134 ). From blower fan  142 , indoor air may be motivated (e.g., across heating unit  132 ) and returned to the indoor area of the room through an indoor outlet  140  defined through housing  114  (e.g., above indoor inlet  138  along the vertical direction V). Optionally, one or more conduits (not pictured) may be mounted on or downstream from indoor outlet  140  to further guide air from air conditioner  100 . It is noted that although indoor outlet  140  is illustrated as generally directing air upward, it is understood that indoor outlet  140  may be defined in alternative embodiments to direct air in any other suitable direction. 
     Outdoor and indoor heat exchanger  120 ,  122  may be components of a thermodynamic assembly (i.e., sealed system), which may be operated as a refrigeration assembly (and thus perform a refrigeration cycle) or, in the case of the heat pump unit embodiment, a heat pump (and thus perform a heat pump cycle). Thus, as is understood, exemplary heat pump unit embodiments may be selectively operated perform a refrigeration cycle at certain instances (e.g., while in a cooling mode) and a heat pump cycle at other instances (e.g., while in a heating mode). By contrast, exemplary A/C exclusive unit embodiments may be unable to perform a heat pump cycle (e.g., while in the heating mode), but still perform a refrigeration cycle (e.g., while in a cooling mode). 
     The sealed system may, for example, further include compressor  126  (e.g., mounted on basepan  136 ) and an expansion device (e.g., expansion valve or capillary tube—not pictured), both of which may be in fluid communication with the heat exchangers  120 ,  122  to flow refrigerant therethrough, as is generally understood. The outdoor and indoor heat exchanger  120 ,  122  may each include coils  146 ,  148 , as illustrated, through which a refrigerant may flow for heat exchange purposes, as is generally understood. 
     As will be further described in detail below, a telescoping plenum  200  may be provided to direct air to or from housing  114 . When installed, telescoping plenum  200  may be selectively attached to (e.g., fixed to or mounted against) housing  114  (e.g., via a suitable mechanical fastener, adhesive, gasket, etc.) and extend through a structure wall  150  (e.g., an outer wall of the structure within which air conditioner  100  is installed). In particular, telescoping plenum  200  extends along an axial direction X (e.g., parallel to the transverse direction T) through a hole or channel  152  in the structure wall  150  that passes from an internal surface  154  to an external surface  156 . 
     The operation of air conditioner  100  including compressor  126  (and thus the sealed system generally), blower fan  142 , outdoor fan  124 , heating unit  132 , and other suitable components may be controlled by a control board or controller  158 . Controller  158  may be in communication (via for example a suitable wired or wireless connection) to such components of the air conditioner  100 . By way of example, the controller  158  may include a memory and one or more processing devices such as microprocessors, CPUs or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of air conditioner  100 . The memory may be a separate component from the processor or may be included onboard within the processor. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. 
     Air conditioner  100  may additionally include a control panel  160  and one or more user inputs  162 , which may be included in control panel  160 . The user inputs  162  may be in communication with the controller  158 . A user of the air conditioner  100  may interact with the user inputs  162  to operate the air conditioner  100 , and user commands may be transmitted between the user inputs  162  and controller  158  to facilitate operation of the air conditioner  100  based on such user commands. A display  164  may additionally be provided in the control panel  160 , and may be in communication with the controller  158 . Display  164  may, for example be a touchscreen or other text-readable display screen, or alternatively may simply be a light that can be activated and deactivated as required to provide an indication of, for example, an event or setting for the air conditioner  100 . 
     Turning now especially to  FIGS. 2 through 5 , an exemplary telescoping plenum  200  will be described in greater detail.  FIGS. 3 through 5  in particular provide various views of telescoping plenum  200  in isolation and with an interior portion  210  and an exterior portion  212  separated for clarity. 
     Although shown as separated in  FIGS. 3 through 5 , it is noted that the assembled telescoping plenum  200  provides interior portion  210  and exterior portion  212  in sliding engagement (e.g., such that exterior portion  212  is movable along the axial direction X on interior portion  210 ). For instance, at least one of interior portion  210  and exterior portion  212  may be selectively nested within each other (e.g., such that the nested member is surrounded about the axial direction X, at least in part, by the receiving member). In some such embodiments, interior portion  210  is selectively nested within exterior portion  212 , as shown in  FIGS. 1 and 2 . 
     Interior portion  210  of telescoping plenum  200  includes a duct wall  216  that is formed about the axial direction X (e.g., when mounted through wall channel  152 ). Duct wall  216  may be formed according to any suitable hollow shape, such as conduit having a rectangular profile (shown), defining an air channel  214  to guide air therethrough. Moreover, duct wall  216  may be formed from any suitable non-permeable material (e.g., steel, aluminum, or a suitable polymer) for directing or guiding air therethrough. 
     When assembled, interior portion  210  is selectively attached to housing  114 . Specifically, interior portion  210  may be mounted proximal to outdoor portion  110  or distal to indoor portion  112 . In some such embodiments, interior portion  210  is fixed to or mounted against housing  114  (e.g., via one or more suitable mechanical fasteners, adhesives, gasket, etc.) about at least a portion of rear opening  116 . The duct wall  216  of interior portion  210  may surround, for instance, outdoor outlet  130 . Additionally or alternatively, the duct wall  216  of interior portion  210  may surround outdoor inlet  128 . 
     In certain embodiments, interior portion  210  further includes an outer flange  220  that extends in a radial direction (e.g., perpendicular to the axial direction X) from duct wall  216 . Specifically, outer flange  220  extends radially outward (e.g., away from at least a portion of the axial direction X or the duct wall  216  of interior portion  210 ). Outer flange  220  may thus avoid interference an airflow or flow path within air channel  214 . 
     Outer flange  220  may extend radially outward from all or, alternatively, merely a portion of, duct wall  216 . For instance, as shown in the exemplary embodiments, outer flange  220  extends from a top end  222  of the duct wall  216  of interior portion  210 . In the illustrated embodiments, outer flange  220  also extends from both sides  230 ,  232  of the duct wall  216  of interior portion  210 . It is understood, however, that alternative embodiments, may provide outer flange  220  at another (e.g., one or more) suitable locations along the profile of the duct wall  216  of interior portion  210 . Optionally, an internal plate  221  may extend radially inward from duct wall  216  (e.g., at or from the bottom end  238 ), such that a sub-portion (i.e., less than a whole) of air channel  214  is obstructed. 
     When assembled, outer flange  220  may be placed against (e.g., in contact—direct or indirect) with an internal surface  154  of the structure wall  150 . Thus, outer flange  220  may be located in or pressed into engagement with the internal surface  154  as at least a portion of duct wall  216  of interior portion  210  extends through wall channel  152  (e.g., while housing  114  is held opposite the duct wall  216  of interior portion  210 , such as within an interior or indoor area of the structure). 
     Exterior portion  212  of telescoping plenum  200  includes a duct wall  218  that is formed about the axial direction X (e.g., when mounted through wall channel  152 ). Duct wall  218  may be formed according to any suitable hollow shape, but is generally formed to complement the shape of the duct wall  216  of interior portion  210 . For instance, the duct wall  218  of exterior portion  212  may be formed as a similar shape of the duct wall  216  of interior portion  210 , but with a unique size. In some such embodiments, the profile dimensions (e.g., vertical length and lateral width) of exterior portion  212  are larger than the dimensions of interior portion  210 , such that interior portion  210  can be selectively nested within exterior portion  212 . In certain selectable positions, the duct wall  218  of exterior portion  212  may further define and extend air channel  214  from interior portion  210  (e.g., to guide air therethrough). Similar to interior portion  210 , the duct wall  218  of exterior portion  212  may be formed from any suitable non-permeable material (e.g., steel, aluminum, or a suitable polymer) for directing or guiding air therethrough. 
     When assembled, exterior portion  212  is selectively movable relative to interior portion  210 . For instance, exterior portion  212  may be mounted in slidable engagement with interior portion  210  (e.g., to move along the axial direction X as directed or positioned by an installer). Thus, as the distance (e.g., axial or transverse distance) between housing  114  and interior portion  210  remains generally fixed, the distance (e.g., axial or transverse distance) between housing  114  and exterior portion  212  may be selectively varied. 
     As shown, the duct wall  218  of exterior portion  212  has an inner surface  244  directed toward air channel  214  or interior portion  210 , as well as an outer surface  246  directed away from air channel  214  or interior portion  210 . In certain embodiments, outer surface  246  is provided as a flange-less outer surface  246 . At the outer surface  246 , the duct wall  218  of exterior portion  212  may thus be generally parallel to, for example, axial direction X or transverse direction T and free of any flanges or obstruction thereon (e.g., as provided in conventional plenums). The flange-less outer surface  246  may extend from a front end  248  of exterior portion  212  to a rear end  250  of exterior portion  212 . 
     When assembled, exterior portion  212 , including flange-less outer surface  246  may extend through (e.g., selectively pass through) wall channel  152  along the axial direction X. Advantageously, exterior portion  212  may pass through wall channel  152  (e.g., move relative thereto) without striking or contacting either the internal surface  154  or external surface  156  of structure wall  150 ). In some such embodiments, the rear end  250  is selectively held or positioned outside of wall channel  152 , such as beyond the external surface  156  thereof (e.g., in an ambient environment opposite of housing  114  relative to structure wall  150 ). Optionally, a caulk bead  252  (i.e., adhesive or sealant caulk) may be positioned on or along at least a portion of the flange-less outer surface  246  and join outer surface  246  to the external surface  156  of structure wall  150  (e.g., about or outside from wall channel  152 ). 
     Although outer surface  246  may be a flange-less surface, an inner lip  254  may extend radially inward from the duct wall  218  of interior portion  210 . For instance, inner lip  254  may extend radially inward from inner surface  244  (e.g., toward axial direction X or air channel  214 ). As shown, only a sub-portion (i.e., less than a whole) of air channel  214  is obstructed by inner lip  254 . In some such embodiments, inner lip  254  extends radially inward from the duct wall  216  at one or both of the lateral sides  234 ,  236 . 
     In some embodiments, telescoping plenum  200  includes a divider wall  256  within air channel  214 . When assembled, divider wall  256  defines a separate upper passage  258  and lower passage  260 . For instance, divider wall  256  may extend along the lateral direction L from one lateral side of telescoping plenum  200  to the other lateral side. Generally, upper passage  258  and lower passage  260  may divide or define two discrete air flow paths for air channel  214 . For instance, upper passage  258  may be defined within telescoping plenum  200  between divider wall  256  and interior portion  210  or exterior portion  212 . Similarly, lower passage  260  may be defined within telescoping plenum  200  between divider wall  256  and interior portion  210  or exterior portion  212  (e.g., below upper passage  258  along the vertical direction V). When assembled, upper passage  258  and lower passage  260  may be fluidly isolated by divider wall  256  (e.g., such that air is prevented from passing directly between passages  258  and  260  through divider wall  256 , or another portion of telescoping plenum  200 ). Upper passage  258  may be positioned upstream from outdoor inlet  128 . Lower passage  260  may be positioned downstream from outdoor outlet  130 . 
     As shown, divider wall  256  may include a separate interior divider panel  262  and exterior divider panel  264 . In some such embodiments, interior divider panel  262  is generally fixed to interior portion  210 , and exterior divider panel  264  is fixed to exterior portion  212 . As exterior portion  212  moves relative to interior portion  210  (e.g., sliding along the axial direction X), so too may exterior divider panel  264  move relative to interior divider panel  262 . When assembled, exterior divider panel  264  may rest on or beneath interior divider panel  262 . Exterior divider panel  264  may be axially slidable along interior divider panel  262  (e.g., such that exterior and interior divider panels  264 ,  262  act as a single air-guiding wall). 
     In certain embodiments, interior divider panel  262  is fixed to the duct wall  216  of interior portion  210 . For instance, interior divider panel  262  may be fixed to an inner surface  240  of the duct wall  216  at a first or second side  230 ,  232  of telescoping plenum  200 . Additionally, interior divider panel  262  may include one or more side flaps  268  fixed to the inner surface  240  (e.g., via a suitable mechanical fastener, adhesive, weld, solder, etc.). In some embodiments, interior divider panel  262  spans the entire lateral width from a first side  230  to a second side  232  of interior portion  210 . As an example, a discrete side flap  268  may be provided at both first side  230  and second side  232 . Optionally, the discrete side flaps  268  may extend downward (e.g., toward lower passage  260 ) from interior divider panel  262 . 
     In additional or alternative embodiments, exterior divider panel  264  extends partially along or across the lateral width of exterior portion  212  (i.e., not across the entirety of the lateral width defined by exterior portion  212  within air channel  214 ). In particular, a gap or side channel  266  may be defined between exterior divider panel  264  and an inner surface  244  of the duct wall  218  of exterior portion  212 . In some such embodiments, the side channel  266  extends laterally (i.e., along the lateral direction L such that a void is defined along the lateral direction L). Moreover, the side channel  266  may be positioned vertically between upper passage  258  and lower passage  260 . Optionally, a discrete side channel  266  may be provided at both the first side  234  and second side  236  of exterior portion  212 . The side channel  266  may be sized to accommodate at least a portion of interior portion  210 , such as the duct wall  216  or side flap  268  of interior portion  210 . Thus, at least a portion of the duct wall  216  of interior portion  210  may be received within side channels  266 . In some such embodiments, exterior divider panel  264  is located below (e.g., at a lower relative position along the vertical direction V than) interior divider panel  262 . 
     In optional embodiments, exterior divider panel  264  is fixed to inner lip  254 . For instance, exterior divider panel  264  may include a forward flap  270  (e.g., extending downward toward lower passage  260 ) fixed to inner lip  254  (e.g., via a suitable mechanical fastener, adhesive, weld, solder, etc.). Optionally, forward flap  270  may be fixed to inner lip  254  at both the first side  234  and second side  236  of exterior portion  212 . 
     During installation, exterior portion  212  may be selectively and advantageously moved on interior portion  210  through the wall channel  152  along the axial direction X until a desired position is reached (e.g., until the rear end of exterior portion  212  is located in an ambient environment and spaced apart from the external surface  156  of the structure wall  150 ). One of more fasteners (e.g., mechanical fasteners—such as screws, nuts, or clips—adhesives, etc.) may be used to secure the relative position of exterior portion  212  to interior portion  210 . For instance, one or more set screws may extend through (and join) interior divider panel  262  and exterior divider panel  264 . The caulk bead  252  may later be applied to the flange-less outer surface  246 , sealing and securing telescoping plenum  200  to the structure wall  150 . 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.