Patent Publication Number: US-11384945-B2

Title: Quiet room air conditioning unit

Description:
CLAIM OF PRIORITY 
     This application claims priority to the US Provisional Utility Patent Application No. 63/035,535, which was filed on 5 th  of Jun. 2020, the contents of which are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to window cooling and heating units, namely a stand-alone room air conditioning unit having the noisiest component installed behind a wall. 
     BACKGROUND OF THE INVENTION 
     Modern air conditioning technology has been invented at the turn of the twentieth century. A room air conditioning unit was not invented until 1930s. The residential sector did not adopt a room temperature control unit on a massive scale until the 1950s. Since then, the configuration a representative unit has been virtually unchanged, with slight improvements introduced periodically to increase performance or to improve efficiency. 
     Like all air conditioning units, a room unit requires two coil systems, at least one fan and a compressor. The noisiest element of the unit is the compressor, followed by the fan. One solution to solving the noise problem calls for an internal condenser coil and fan to be housed in a separate unit mounted on the inside of a room, while another unit containing evaporator coils, fan and compressor is placed somewhere outside, and usually mounted on especially installed brackets along the exterior wall of a building. The two units are connected using rigid piping for liquid/gas exchange, and they often share circuitry. While this solution clearly resolves the noise issue, it also increases the cost of the unit, as well as installation, operating costs of and environmental costs of a room unit. Furthermore, such installation necessitates involvement of a professional HVAC technician and a building contractor. 
     Most room units are window units. A window provides a ready opening for the evaporator coil, without the need of making holes in a wall. However, doing so compromises the use of the window as a source of light and fresh air and obstructs the windowsill that is now covered by the air conditioning unit. Furthermore, since a window unit is largely held back from falling out by the window in which it is mounted, to avoid an instance of a falling air conditioning system down many floors to the street below, such units cannot be installed in a building having more than a couple of floors unless a special wall port is provided. 
     Furthermore, a window unit, whether it is installed in a window or into an opening in a wall made for this purpose, is either attached to the window pane, or mounted on special brackets pinned into the exterior wall below the window or opening. Such installation usually leaves the window with permanent damage. Since a window unit must necessarily be narrower than the window itself, the empty void is covered using ugly accordion expanders or other makeshift materials and some tape. 
     The aforementioned problems have not gone unnoticed, and prior does provide some examples of units that attempt to resolve some of the issues identified above. 
     BRIEF DESCRIPTION OF THE RELATED ART 
     One such example is for U.S. Pat. No. 2,737,788 to Buttner. In this example the main portion of the unit is hung outside the window. However, the width of the gap straddling the windowsill is not adjustable, and the windowsill is still sacrificed. 
     Another example is U.S. Pat. No. 3,439,219 to Brugler. In this example, the unit contains a gap to accommodate the opening and closing of the windowpane. Closing the windowpane should block out some of the noise, however, a window is not as thick as a wall. Therefore, far more noise will leak back into the room than if the wall is providing the blocking. Furthermore, the window is still obstructed, and the windowsill is still sacrificed. Another key difference is that the gap in Brugler is not adjustable. Finally, this unit is severely imbalanced, with the heavier end being outside of the room. This requires a deployment of a separate frame or professional installation to secure the device. 
     Yet another example is the US. Pat. App. 2017/0284683 to Gallo. This reference provides for a means to adjust the gap and the gap is used for straddling a support surface such that a wall stands in between the room and the noise. However, unlike the disclosed invention, the two halves in Gallo are structurally coexistent and cannot exist independently. Therefore, in an even when a component in one of the sections breaks, one may need to replace the entire unit. On the contrary, in the disclosed device, if the particular component cannot be changed by itself, only the container where such component is installed needs to be replaced. 
     Various implements are known in the art but fail to address all of the problems solved by the invention described herein. 
     SUMMARY OF THE INVENTION 
     The disclosed apparatus is a room unit which may function as an air conditioning unit, or as an air cooling and heating unit, depending on which internal components are installed. The internal components are separated into two containers that are independent from each other. Each container is attached to an overhead frame. The attachment and the strength of the frame is designed to securely hold the containers suspended over a support surface. 
     The gap is used to mount the unit over a support surface, such as a window frame or a wall. Each frame slides in correspondence to each other. Therefore, the width of the gap between the containers is fully adjustable. The frame supporting each container extends to one side beyond the perimeter of the container, and this extension is covered by a plate. Such plates of first and second containers overlap each other and function as a strengthening element for the frame, as a way to seal the frame from below and as a conduit. 
     The components of the two containers are linked together using flexible piping, which is deliberately made with additional length to accommodate a lengthening of the conduit. The two frames are completely separable by having the flexible piping connect together inside the conduit using hermetic snap connectors. 
     Finally, the top of each frame is covered by a flat cover. The flat cover is designed to give the disclosed device a uniform profile, such that the utility of a windowsill functioning as a shelf, which becomes obstructed by the deployment of the unit, is restored. 
     When the unit is deployed thought a wall, an opening need only be big enough to accommodate the width and height of the conduit. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1 &amp; 2  show the disclosed invention installed in a residential environment. 
         FIG. 3  is a cutaway sideview of the disclosed invention. 
         FIG. 4  is a closeup diagram of flexible tubing with decoupling connectors. 
         FIG. 5  is a fully assembled device demonstrating intake filtration and top cover. 
         FIGS. 6 &amp; 7  are exploded diagrams of the components making up the disclosed device. 
         FIG. 8  is a device, shown deployed through a slot in a wall rather than a window. 
         FIG. 9  demonstrates a side view of the disclosed device, with stability levers deployed. 
         FIG. 10  is a demonstration of a resident able to utilize a fire escape despite the presence of an installed air conditioning window unit. 
         FIG. 11  is a demonstration of a hot/cold window unit (heat pump) embodiment, showing a safety shutoff switch. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The preferred embodiments of the present invention will now be described with reference to the drawings. Identical elements in the various figures are identified with the same reference numerals. 
     Reference will now be made in detail to embodiment of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto. 
       FIG. 1  demonstrates the disclosed air conditioning (AC) unit  2  deployed inside a window  3 . Like in most window units, a double (as shown) or triple hung casement window is the preferred window installation. The lower pane  8  is lifted slightly to allow the passage of the conduit  22 . The exterior unit  20  and the interior unit  30  are both suspended from the conduit frame  22 . The windowsill portion of the window frame  12 , carries the entire weight of the exterior and interior units  20  and  30 , respectively. It should be noted that upon installation of the displayed unit, that the lower pane  8  is lowered to within approximately five centimeters of the lower member of the frame  5 , to allow for the thickness of the conduit frame  22 . Once the unit  2  is in place, both windowpanes  6  and  8  may be operated as before. As appreciated through observation of parts shown in  FIG. 1 , no portion of the windowpanes  6  and  8  are obstructed in any way. A refrigerant charging manifold  93  may be used to monitor, discharge and recharge the level of refrigerant coursing through the plurality of tubing  72  and  90 . 
       FIG. 2  provides a demonstration of the interior view of the wall  10  within an interior space  14 . The interior unit  30  of the disclosed device  2  is suspended from the conduit frame  22 . The conduit frame  22  lays directly over the lower window frame member  16 , which may also form a windowsill. The surface formed by the first wall  24  replaces the windowsill  16  that is now blocked by the conduit fame  22 . Indeed, the first wall  24  enhances the function of the windowsill it replaces by providing a larger and more evenly distributed surface area. 
     The sideview of the disclosed air conditioning unit  2  is shown in  FIG. 3 . The conduit frame  22  is comprised of two half frames  38 . Each half-frame having an upright rail  42  forming a lateral member on either side of the crossmember  44 . The upright rail  42  is formed from an upright wall  40  and second wall  41  extending at an angle, preferably a right able, from the free end of the upright wall  40 , in the direction overhanging the crossmember  44 . 
     The upright rails  42   a  and the upright rails  42   b  that together form the two halves of the two half frames  38 , are in slidable association with each other, meaning that they can be extended to increase the gap between the first container  50  and the second container  60 , or shortened to reduce the gap between the first container  50  and the second container  60 . A tubal brace  46  may be added to each rail  42 . The tubal brace being on either side of the middle cross member  48 , which covers the gap between the first container  50  and the second container  60 . It is appreciated that rails  42   a  and  42   b  are fully telescopic with respect to each other. 
     The first container  50  is made of four walls  52 , that form a perimeter around the bottom wall  54 . The exterior wall  53  contains a gap to permit exterior facing fins. The first container  50  is permanently attached beneath the half frame  38  of the exterior unit  20 . The second container  60  is made of four walls  62  that form a perimeter around the bottom wall  64 . The interior facing wall  63  contains a gap for the air exchange grille. The second container  60  is permanently attached to the underside of the half frame  38  of the interior unit  30 . 
     It is preferred that the wall  52  that is facing the gap between the first container  50  and the second container  60  includes at least one stability arm  56  that is axially coupled to a pivot  58 . The stability arm  56  containing a swiveling and adjustable foot  57 . As will be shown in later figures, the purpose of the stability arm  56  is to achieve a substantially immobile balance when the leg  56  is jammed against an outer wall of a structure. 
     The internal components that are visible is an evaporating coil  70  a plurality of refrigerant tubes  72 , a blower compartment  74 , a control board  73 . The control board is a switch that controls the internal air conditioning components of the disclosed device housed in the external and internal units  20  and  30 , respectively. The components of the external unit  20  are connected to the switch via wiring that passes over the middle crossmember component  48  through flexible tubing  90 . In the external unit, visible is the compressor  82  and condenser coil and blower  80 . The tubes  90  spanning the middle cross member  48  are preferably made of flexible materials and linked together using snap, twist or bayonet type connectors  92 . It should be appreciated, that when the snap connectors contain an internal valve that is close when the connector is not attached to a corresponding connector. As such the outer unit  20  and the inner unit  30  may be pulled apart from each other and reconnected again during mountings, dismounting and servicing of the disclosed unit  2 . 
     The perspective view shown in  FIG. 4  is an up-close diagram of flexible tubing  90 . The flexible tubing is required to link the air conditioning components in the external unit  20  to the air conditioning components in the internal unit  30 . The tubing  90  may be comprised of evaporation pump hose  90   a , a wiring conduit  90   b  and refrigerant tubing  90   c . The tubing is connected at the middle cross member  48  with snap connectors  92  or twist-off connectors  92   a . the evaporation pump hose  90   a  carries condensation collected in the evaporator pan  94  over the middle cross member  48  and into the external unit  28 , where it will be channeled to the outside via the spout  96 . In a purely self-contained embodiment, the spout  96  would be replaced with an evaporator coil, that would turn the liquid into vapor so as not to produce a stream of water dripping from the exterior unit  20 . Appreciably, this feature would be especially desirable on street side and high-rise installations. Since  FIG. 4  is a perspective view, also visible in this diagram is a control panel  73 , an air intake grill  98  and blow vents  100 . 
     A fully assembled unit is shown in  FIG. 5 . An intake filter  102  is inserted through a slot  104  in the sidewall. The conduit frame  22  is showing a cover  110 . The cover  110  is split into two overlapping components  110   a  and  110   b  that slide beneath each other so that the external and internal units  20  and  30 , respectively, may be moved apart or moved closer together without removing the cover  110 . It is appreciated that with the cover  110  being in place, the middle cross member  48  and the upright rails  42  form a conduit of approximately 3.8 centimeters tall, encompassing the entire width of the unit  2 . 
     The conduit frame  22  may be assembled utilizing any number of components in a plurality of different configurations. Demonstrated in  FIGS. 6 and 7  is the preferred embodiment showing a first container  50  and a second container  60 . A frame  22  is made of two half frames  38   a  and  38   b  that telescope in respect to each other. Each half frame is composed of parallel upright rails  42   a  or  42   b , a cross member  44  and a middle cross member  48 . It is noted that the middle cross member  48 , like everything in the middle section between the first and second containers  50  and  60 , is made of two halves, to enable for slidable association between members. The middle cross member  48  is therefore made of two halves  48   a  and  48   b . The brace  46  is shown to be part of the half frame  38   b . However, the brace  46  may be placed on either of the half frames. 
     The half frames  38   a  and  38   b  are riveted, welded, or attached with fasteners to the top end  118  of the container. Once attached, the gap  116  may be used to access internal components of the air conditioning unit  2  for service and repair. The entire frame is then covered with a lid  110 , formed from two half covers  110   a  and  110   b . The front of the lid  110  features a lip  112 . The lip  112  may exist on three sides of the lid  110 , except for the side that is facing the opposite half frame. 
     Demonstrated further in  FIG. 7  are stability arms  56 , that are pivotably connected through a pivot  58  a hinge  59 . The stability members  56  may instead be protrusions or legs facing the exterior surface of a wall. The stability arms  56  are a precautionary measure and the unit itself is already substantially balanced without their use. 
     The disclosed air conditioning device  2  can be easily installed through a slot in the wall as shown in  FIG. 8 . The slot  120  through the wall  7  may be just slightly wider and taller than the conduit frame  22 . Alternatively, since the disclosed embodiment utilizes flexible tubing  90  ( FIG. 4 ) these can be threaded through using individual openings and no slot is then required through the wall  7 . 
     The use of balancing arms  56  is further demonstrated in a sideways sectional  FIG. 9 . The unit is balanced over the windowsill and may be done by moving the unit in a lateral direction  119 , until a balance is achieved. Alternatively, one can extend the external unit  20  a little further from the wall  7  and then direct the external unit  20  to be biased to swing in the direction  121 , which is the force used to jamb the adjustable feet  57  of the balancing arms  56  against the wall  7 . Alternatively, a substantially straight protrusions facing the exterior of the wall  7  and placed substantially toward the bottom of the structure facing wall of the exterior unit  20 , would achieve the same gravity driven stability. The actual dimensions of the external and internal units  20  and  30 , which are clearly visible here may vary depending on the size and capacity of internal components. 
     The disclosed unit  2  may be used in a fire escape setting, or in any setting where the usage of a window  3  needs to remain almost completely unobstructed and undeterred by the presence of the installed window air conditioning unit.  FIG. 10  demonstrates a subject climbing out of the window  3  and over the disclosed unit  2 . The majority of the window aperture is still usable as a point of access and egress despite the presence of the unit in the window  5 . 
     Finally, it should be appreciated that the air conditioning unit shown  2  is not limited to usage to cool the internal atmosphere, but also as a means to warm it. To do so, one of the containers  50  or  60  must retain a three-way valve  130  which allows for the reversal of the flow of refrigerant in a way that the roles of inner and out coils reverse. To avoid damaging the external coils  80 , the disclosed device will preferably be equipped with a temperature sensor  125 , which when connected to a solenoid  123 , which forms a second switch of the unit, and which will disable the warming function of the unit if the outside temperature becomes too cold for safe or practical operation of the evaporator coil  80 . 
     Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention.