Abstract:
An adapter for controlling airflow between a first element and a second element in an air conditioning system is provided including a frame having a first frame piece and a second frame piece. A portion of the second frame piece overlaps the first frame piece. The second frame piece slides relative to the first frame piece making a dimension of the frame adjustable. An upper portion of the frame attaches about an end of the first element and a lower portion of the frame attaches about an end of the second element.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/647,618 filed May 16, 2012, the contents of which are incorporated herein by reference thereto. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The invention relates generally to heating and cooling systems and, more particularly, to a connection of an indoor coil within such heating and cooling systems. 
         [0003]    Air conditioning and heat pump systems include two major components, an outdoor unit and an indoor coil. Within the system, the indoor coil is typically positioned directly downstream from an outlet of a furnace, such as a gas furnace for example. In some air conditioning and heat pump systems, the outlet of the furnace outlet is not the same size as the inlet of the adjacent indoor coil. Most commonly, the width of the indoor coil inlet is larger than the width of the furnace outlet, thereby allowing air to escape at the junction between the two. This difference in size results in an undesirable airflow through the indoor coil because the airflow is concentrated in areas across the coil. 
         [0004]    During installation of such a system, a mechanic must develop a means for mating the furnace outlet with the indoor coil inlet at the installation site. One solution is to create “block-off” or filler plates from sheet metal to prevent air escaping from the system. Though installation of “block off” plates may prevent a leak in the airflow, this on-site process is time consuming, and customers find this solution aesthetically displeasing because the “block-off” plates do not match the look of the adjacent system components. In addition, the use of block off plates often exacerbates the size difference problems resulting in an undesirable airflow through the indoor coil because the airflow is concentrated in areas across the coil. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0005]    According to an embodiment of the invention, an adapter for controlling airflow between a first element and a second element in an air conditioning system is provided including a frame having a first frame piece and a second frame piece. A portion of the second frame piece overlaps the first frame piece. The second frame piece slides relative to the first frame piece making a dimension of the frame adjustable. An upper portion of the frame attaches about an end of the first element and a lower portion of the frame attaches about an end of the second element. 
         [0006]    According to yet another embodiment of the invention, a system is provided including a furnace and an indoor coil located directly downstream from the furnace. An adapter includes a first frame piece and a second frame piece. A portion of the second frame piece overlaps the first frame piece. The second frame piece slides relative to the first frame piece making a dimension of the frame adjustable. An upper portion of the frame attaches about an end of the first element and a lower portion of the frame attaches about an end of the second element. 
         [0007]    According to yet another aspect of the invention, a method for installing an adapter between a first component and a second component in a system is provided including adjusting the adapter to a size of an end of a first component. A fastener is then inserted through a plurality of aligned holes of the adapter. The adapter is connected about an end of the second component. Additional fasteners are then inserted through the remainder of the plurality of aligned holes of the adapter. The adapter is then connected about an end of the first component. 
         [0008]    These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         [0009]    The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which: 
           [0010]      FIG. 1  is a schematic illustration of an HVAC system; 
           [0011]      FIGS. 2   a - 2   d  are front views of exemplary furnace and indoor coil interfaces; 
           [0012]      FIG. 3  is an exemplary furnace and indoor coil interface according to an embodiment of the invention; 
           [0013]      FIG. 4  is a perspective view of an indoor coil adapter in accordance with an embodiment of the invention; 
           [0014]      FIG. 5  is a perspective view of an indoor coil adapter in accordance with an embodiment of the invention; and 
           [0015]      FIG. 6  is a perspective view of an indoor coil adapter in accordance with an embodiment of the invention; 
           [0016]      FIG. 7  is a perspective view of an indoor coil adapter in accordance with an embodiment of the invention; 
           [0017]      FIG. 8  is an exploded view of an indoor coil adapter assembled in an HVAC system in accordance with an embodiment of the invention; and 
           [0018]      FIG. 9  is a method for installing an indoor coil adapter in an HVAC system. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0019]    Referring now to  FIG. 1 , an illustrated heating ventilation and air conditioning (HVAC) system  20  includes an outdoor air conditioner or heat pump unit  30 . Disposed within the building is a furnace  45 . An indoor coil  40  is positioned directly adjacent the furnace  45  such that the indoor coil  40  is generally aligned with the furnace  45 . The air conditioner/heat pump  30 , connected to the indoor coil  40  refrigerant lines  35 , heats or cools the air A passing over the indoor coil  40  before it is distributed. A supply duct  50  carries the air A from the indoor coil to various parts of the building which the HVAC system  20  serves. As the air A is distributed to the atmosphere of the building, air A will either absorb heat to cool the atmosphere or release heat to warm the atmosphere. Air that has undergone this release or absorption of heat is designated as A′. Air A′ returns to the HVAC system  20  through an intake vent  55 . The air A′ travels through a main return duct  60  which delivers the air A′ back to the furnace  45 . In one embodiment, an adapter  100  provides an interface between the furnace  45  and the indoor coil  40  to ensure that airflow is not lost between the two components. 
         [0020]    With reference to  FIG. 2 , the size of the inlet to the indoor coil  40  and the placement of the indoor coil  40  may vary relative to the furnace  45 . In some applications, as illustrated in  FIG. 2   a , the indoor coil  40  and the furnace  45  may be equal in size and aligned. In these applications, the exemplary adapter  100  has a generally rectangular cross section. In other HVAC applications, the inlet of the indoor coil  40  can be larger than the outlet of the furnace  45 . The oversized indoor coil  40  may be centered relative to the furnace ( FIG. 2   b ), such that air gaps are present on both sides of the indoor coil  40 . In such applications, the adapter  100  has a cross-section of a generally isosceles trapezoid to prevent a loss of airflow between the furnace  45  and the indoor coil  40 . In even other HVAC applications, the oversized indoor coil  40  may be offset to one side of the furnace  45  (see  FIGS. 2   c  and  2   d ). In such applications, an exemplary adapter  100  is used to prevent a loss of airflow between the indoor coil  40  and the furnace  45 . The cross-section of an adapter  100  used with an offset indoor coil  40  is a generally right angle trapezoid. The same adapter  100  may accommodate an offset in either a first direction or a second, opposite direction. The oversized indoor coil  40  is centered relative to the furnace ( FIG. 2   b ), such that air gaps are present on both sides of the indoor coil  40 . Referring to  FIG. 3 , systems having an oversized air coil  40  offset to one side and an adapter  100 , may include an indoor air quality device (IAQ)  80  installed in the gap formed between the furnace  45  and the main return duct  60 . 
         [0021]    Referring now to  FIGS. 4-6 , multiple embodiments of the adapter  100  are illustrated. An exemplary adapter  100 , illustrated in  FIG. 4 , is designed for use in an HVAC system  20  where the indoor coil  40  and the furnace  45  have the same width (See  FIG. 2   a ). The adapter  100  consists of a frame made from a first frame piece  102  and a second frame piece  140 . The first frame piece  102  has a first wall  105  and a first arm  106  and a second arm  108  connected to and extending generally perpendicularly from the first wall  105  in a general C-shape. In one embodiment, the first arm  106  and the second arm  108  are the same length. In one embodiment, the first frame piece  102  is made from a single piece. In another embodiment, the first arm  106  and the second arm  108  are separate pieces bonded to the first wall  105 , such as by welding or brazing for example. A flange  110  extends along the top edge of the first frame piece  102  and a second flange  115  extends along the bottom edge of the first frame piece  102 , opposite the top edge. The flanges  110 ,  115  may be formed integrally with the first frame piece  102 , or alternately, may be additional pieces mounted to the first frame piece  102 . Disposed near the free end of the first arm  106  and the second arm  108  are a plurality of holes  120 ,  125  extending from the top edge to the bottom edge of the first frame piece  102 . 
         [0022]    The second frame piece  140  includes a second wall  142 . A third arm  144  and a fourth arm  146  extend generally perpendicularly from opposing sides of first wall  142  in a general C-shape. In one embodiment, the third arm  144  and the fourth arm  146  are the same length. In one embodiment the third arm  144  has a length equal to or shorter than the length of the first arm  106 , and the fourth arm  146  has a length equal to or shorter than the length of the second arm  108 . Similar to the first frame piece  102 , a flange  145  extends along the top edge of the second frame piece  140  and a second flange  150  extends along the bottom edge of the second frame piece  140 , opposite the top edge. A plurality of holes  155  and  160  are disposed across the length and height of the third arm  144  and fourth arm  146  respectively. 
         [0023]    When assembled, a portion of the top flange  145  is adjacent top flange  110  and a portion of the bottom flange  150  is adjacent bottom flange  115  such that movement of the second frame piece  140  is limited by the top and bottom flanges  110 ,  115  of the first frame piece  102 . The third arm  144  is located adjacent the first arm  106  and the fourth arm  146  is disposed adjacent the second arm  108 . Assembled, at least a portion of the first arm  106  and the third arm  144  overlap and at least a portion of the second arm  108  and the fourth arm  146  overlap. The second frame piece  140  is slidable relative to the first frame piece  102  to vary the overlap between the sets of arms. By sliding the second frame piece  140  relative to the first frame piece  102 , the length of the generally rectangular adapter  100  is varied for each application. When the second frame piece  140  is in the correct position relative to the first frame piece  102  for an application, a fastener  175  is inserted through aligned holes  120  and  155 , and similarly aligned holes  125  and  160 . In one embodiment, screws are used to connect the first frame piece  102  and the second frame piece  140 . Flanges  110 ,  145  create an upper lip around the adapter  100  for engagement with an end of the indoor coil  40 . A portion of flanges  110 ,  145  extend in the direction of the indoor coil  40  to limit the movement of the adapter  100  relative to the indoor coil  40  when being attached. Similarly, flanges  115 ,  150  create a lower lip around the adapter  100  for engagement with an end of the furnace  45 . A portion of flanges  115 ,  150  extend in the direction of the furnace  45  to properly locate the adapter  100  relative to the furnace  45  when installing the adapter  100 . 
         [0024]    Referring now to  FIG. 5 , an exemplary adapter  100  is illustrated for use in an HVAC system where the indoor coil  40  is offset from the furnace  45 . In one embodiment, the second wall  142  of the adapter  100  is at an angle to the plane of first wall  105  to compensate for the offset between the furnace  45  and the indoor coil  40 . Referring now to  FIG. 6 , an exemplary adapter  100  is illustrated for use in an HVAC system where an oversized indoor coil  40  is centered relative to the furnace  45  such that air flow escapes from both sides of the indoor coil  40 . In one embodiment, the adapter  100  includes an angled first wall  105  and an angled second wall  142 . The angle of the first wall  105  and the second wall  142  may be equal, or alternately the angle of the first wall  105  may differ from the angle of the second wall  142 . 
         [0025]    In an alternate embodiment, illustrated in  FIG. 7 , the adapter  200  may consist of four generally L-shaped frame pieces  202 ,  220 ,  240 ,  260 . Each of the four frame pieces includes a first arm and a second arm. In addition, a top flange and a bottom flange extend along the top edge and bottom edge of each frame piece for engagement as described in the previous embodiments. The top flange  208  and the bottom flange  210  of the first arm  204  of the first frame piece  202  slidably engage a top flange  226  and a bottom flange  228  of a first arm  222  of the second frame piece  220 . Similarly, the top flange  246  and the bottom flange  248  of the first arm  204  of the third frame piece  240  slidably engage a top flange  266  and a bottom flange  268  of a first arm  262  of the fourth frame piece  260 . A top flange  212  and a bottom flange  214  of a second arm  206  of the first frame piece  202  slidably engage a top flange  270  and a bottom flange  272  of a second arm  264  of the fourth frame piece  260 . Lastly, a top flange  230  and a bottom flange  232  of a second arm  224  of the second frame piece  220  slidably engage a top flange  250  and a bottom flange  252  of a second arm  244  of the third frame piece  240 . Fasteners  275  may be used to hold adjacent arms in a desired position relative to one another. Together, the first, second, third, and fourth frame pieces  202 ,  220 ,  240 ,  260  form an overlapping frame having an adjustable length and width. An adapter  200  adjustable in two dimensions may be used with any size indoor coil  40  and furnace  45 . 
         [0026]    Referring now to  FIGS. 8-9  a method  200  is provided for connecting an adapter  100  to an HVAC system. To connect an adapter  100  to an HVAC system  20 , the length of the adapter  100  is adjusted to match the size of the outlet of the furnace  45  in block  202 . In block  204 , a fastener  175  is inserted through an aligned hole  120  and hole  155  of an overlapping first arm  106  and the third arm  144 . Similarly, a fastener is inserted through an aligned hole  125  and hole  160  of an overlapping second arm  108  and fourth arm  146  to retain the position of the second frame piece  140  relative to the first frame piece  102 . The adapter  100  is connected to the indoor coil  40 , in block  206 , by inserting a portion of flanges  110  and  145  into the indoor coil  40 . In position, the edge of the adapter  100  should be flush with the edge of the indoor coil  40 . In block  208 , additional fasteners  175  are inserted through aligned holes  120  and  155 , and aligned holes  125  and  160  to maintain the position of the first frame piece  102  and the second frame piece  140  relative to each other. Once the additional fasteners  175  are attached, the adapter  100  is then connected to the outlet of furnace  45  in block  210 . In one embodiment, tape or mastic may additionally be used to seal the interface between the furnace  45  and the adapter  100  and the interface between the adapter  100  and the indoor coil  40 . 
         [0027]    Because at least one dimension of the adapter  100 ,  200  is adjustable, each adapter  100 ,  200  is compatible for use with a plurality of standard size furnaces, such as furnaces having a width of 14 3/16 inches, 17½ inches, and 24½ inches for example. The adapter  100  may be used in retrofit and modernization applications, such as when a new shorter furnace is installed in the system. The adapter  100  additionally improves the effectiveness of the system by causing the air to spread more evenly from the furnace to the indoor coil  40 . Using adapter  100  reduces the installation time of the system because the installer of the air conditioning system will no longer need to fabricate “block-off” plates or custom sheet metal transition at the job site. Also, the overall system will have a more professional look once the adapter  100  is installed because the adapter is manufactured using steel pre-painted the same color as the other system components. 
         [0028]    While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.