Patent Description:
Temporary shelters, such as field hospitals and living quarters, often require cooling and/or heating to maintain a comfortable space to work, eat, and sleep. Portable environmental control units can be shipped with the temporary shelters or otherwise transported to a location in the field to provide cooling and/or heating to these structures. Size and weight restrictions can be imposed on environmental control units to minimize the cost and burden of transporting the units to the field. However, these restrictions limit the capacity and/or efficiency of the environmental control units. It would be desirable to have a portable environmental control unit with improved capacity and/or efficiency with minimal footprint for transport.

Document <CIT> discloses a window type air conditioner, comprising an indoor unit, an outdoor unit and a sliding portion connecting one end of the indoor unit with the outdoor unit: the distance between the indoor unit and the outdoor unit can be adjusted by sliding the sliding portion.

The exemplification set out herein illustrates embodiments of the invention that are not to be construed as limiting the scope of the invention. The invention is defined in the independent claim. The dependent claims define preferred embodiments of the invention. Additional features of the present invention will become apparent to those skilled in the art upon consideration of the following detailed description of illustrative embodiments exemplifying modes of carrying out the invention as presently claimed.

An illustrative expandable environmental control unit (ECU) <NUM> in accordance with the present invention is shown in <FIG>. The ECU <NUM> includes a base section <NUM>, a mobile section <NUM> coupled to the base section <NUM>, and a temperature control system <NUM> coupled to the base section <NUM> and the mobile section <NUM>. The mobile section <NUM> is arranged for movement relative to the base section <NUM> between a collapsed-storage position, shown in <FIG>, and an expanded-use position, shown in <FIG>. The ECU <NUM> is arranged within a first footprint in the collapsed-storage position and is arranged in a larger second footprint in the expanded-use position. The mobile section <NUM> and temperature control system <NUM> are contained within the base section <NUM> in the collapsed-storage position (as shown in <FIG>) to minimize a footprint of the ECU <NUM> for storage and transport. The mobile section <NUM> extends from the base section <NUM> in the expanded-use position (as shown in <FIG>) to provide air flow (as suggested in <FIG>) through an enclosed space, such as a building structure or temporary shelter. Exemplary processes for moving the ECU <NUM> from the collapsed-storage position to the expanded-use position are illustrated in <FIG> and <FIG>. The temperature control system <NUM> is configured to raise or lower a temperature of the air passing through the mobile section <NUM> to provide heated or cooled air to the enclosed space.

In the illustrative embodiment, the temperature control system <NUM> may include a compressor <NUM> and outdoor heat exchangers <NUM>, <NUM> coupled to the base section <NUM> and an expansion device <NUM> and an indoor heat exchanger <NUM> coupled to the mobile section <NUM> for movement therewith relative to the base section <NUM> as shown in <FIG>. The outdoor heat exchangers <NUM>, <NUM> are arranged to exchange heat with air outside of the enclosed space, and the indoor heat exchanger <NUM> is arranged to exchange heat with air flowing through the mobile section <NUM> to provide heated or cooled air to the enclosed space. The compressor <NUM> and outdoor heat exchangers <NUM>, <NUM> are coupled to the expansion device <NUM> and indoor heat exchanger <NUM> by lines <NUM>, <NUM> to form a closed circuit for passage of a working fluid, such as a refrigerant. A reversing valve <NUM> is configured to selectively control a direction of flow of the working fluid through the temperature control system <NUM> to allow heating or cooling of the indoor heat exchanger <NUM> in order to heat or cool the air passing through the mobile section <NUM>. In some embodiments, the reversing valve <NUM> is omitted such that the ECU <NUM> operates solely as an air conditioner (for cooling air passing through the mobile section <NUM>) or heat pump (for heating air passing through the mobile section <NUM>). In some embodiments, other arrangements of the temperature control system <NUM> are contemplated. For example, one of the outdoor heat exchangers <NUM>, <NUM> could be replaced with a wall or panel, or an additional outdoor heat exchanger could be added. In some embodiments, the temperature control system <NUM> could be flipped with the expansion device <NUM> and indoor heat exchanger <NUM> coupled to the base section <NUM> and the compressor <NUM> and one or more of the outdoor heat exchangers <NUM>, <NUM> coupled to the mobile section <NUM>. In some embodiments, the outdoor heat exchangers <NUM>, <NUM> could move relative to the indoor heat exchanger <NUM> from a collapsed-storage position to an expanded-use position.

As shown in <FIG>, the exemplary base section <NUM> may include a housing <NUM> and a fan assembly <NUM> coupled to the housing <NUM>. The mobile section <NUM> includes a carriage <NUM>, an air return <NUM> coupled to the carriage <NUM>, and an air supply <NUM> coupled to the carriage <NUM> opposite from the air return <NUM>. The temperature control system <NUM> is coupled to the housing <NUM> and carriage <NUM>. The carriage <NUM> is arranged for movement relative to the housing <NUM>, and the air return <NUM> and air supply <NUM> are arranged for movement relative to the carriage <NUM> to move the ECU <NUM> between the collapsed-storage and expanded-use positions. The fan assembly <NUM> is configured to pull air through the outdoor heat exchangers <NUM>, <NUM> into a plenum <NUM> of the housing <NUM> to promote heat transfer between the air and the outdoor heat exchangers <NUM>, <NUM> as suggested in <FIG>. The air passes out of the plenum <NUM> through the fan assembly <NUM>. The air return <NUM> is configured to pull air from the enclosed space (such as through a return conduit <NUM>) into a plenum <NUM> of the air return <NUM>, push the air through the indoor heat exchanger <NUM> into a plenum <NUM> of the air supply <NUM> to promote heat transfer between the indoor heat exchanger <NUM> and the air to heat or cool the air, and force the heated or cooled air out of the air supply <NUM> and back to the enclosed space (such as through a supply conduit <NUM>). The air flow through the plenum <NUM> is separate from the air flow through the plenums <NUM>, <NUM>.

The housing <NUM> of the base section <NUM> includes a plurality of posts <NUM> coupled to a platform <NUM> and a lid <NUM> coupled to the posts <NUM> opposite from the platform <NUM> as shown in <FIG>. A flexible panel <NUM> is coupled to the housing <NUM> and is configured to move between a closed position covering a side of the housing <NUM>, as shown in <FIG>, and an opened position extending away from the housing <NUM>, as shown in <FIG>. In the closed position, the panel <NUM> engages with the housing <NUM> to block movement of the mobile section <NUM> from the collapsed-storage position to the expanded-use position. The mobile section <NUM> can move to the expanded-use positon with the panel <NUM> in the opened position.

In the illustrative embodiment, the fan assembly <NUM> may include a fan unit <NUM>, clamp members <NUM>, <NUM>, and rods <NUM> as shown in <FIG>. The clamp members <NUM>, <NUM> extend around the fan unit <NUM>, and the rods <NUM> are coupled to the fan unit <NUM> and extend through the clamp members <NUM>, <NUM> to allow sliding movement of the fan unit <NUM> relative to the housing <NUM> between an inboard position substantially arranged within the housing <NUM>, shown in <FIG> and <FIG>, and an outboard position extending away from the housing <NUM>, shown in <FIG> and <FIG>. In some embodiments, linear bearings (not shown) are coupled to the clamp members <NUM>, <NUM> and support the rods <NUM> for sliding movement. In some embodiments, one or more plates <NUM> are coupled to the fan unit <NUM> and one or more magnets <NUM> are coupled to the clamp member <NUM> and/or clamp member <NUM> as shown in <FIG>. The plate <NUM> is formed from a magnetically attractive material, such as metal or another magnet, and the magnet <NUM> is arranged to bias the plate <NUM> toward the magnet <NUM> to hold the fan unit <NUM> in the outboard position. In some embodiments, the magnet <NUM> is coupled to the fan unit <NUM> and the plate <NUM> is coupled to the clamp member <NUM> and/or clamp member <NUM>. One or more fasteners <NUM> (<FIG>), such as quarter-turn fasteners, are coupled to the fan unit <NUM> and arranged to selectively engage with the clamp member <NUM> and/or clamp member <NUM> to hold the fan unit <NUM> in the inboard position. In some embodiments, a strap or handle <NUM> is coupled to the fan unit <NUM> to allow a user to move the fan unit from the inboard position to the outboard position.

The carriage <NUM> of the mobile section <NUM> may include a frame <NUM> and slide mechanisms <NUM>, <NUM> coupled to the frame <NUM> as shown in <FIG>. The carriage <NUM> is movable between a stowed position, shown in <FIG> and <FIG>, and a deployed position, shown in <FIG>, <FIG>. The slide mechanisms <NUM>, <NUM> each may include interfacing rail members <NUM>, <NUM> and <NUM>, <NUM>, respectively, that allow substantially linear movement of the frame <NUM> relative to the housing <NUM>. The rail members <NUM>, <NUM> may be coupled to the housing <NUM> and the rail members <NUM>, <NUM> may be coupled to the frame <NUM>. In some embodiments, other mechanisms may be used in place of the slide mechanisms <NUM>, <NUM>, such as hinges. In some embodiments, the slide mechanisms <NUM>, <NUM> are omitted and a user can freely move the mobile section <NUM> relative to the base section <NUM> and mount the mobile section <NUM> on the housing <NUM> or a separate stand.

In the illustrative embodiment, the expansion device <NUM> and indoor heat exchanger <NUM> of the temperature control system <NUM> may be coupled to the frame <NUM> for movement therewith relative to the base section <NUM>, and the lines <NUM>, <NUM> are flexible to accommodate the movement of the expansion device <NUM> and indoor heat exchanger <NUM> relative to other components of the temperature control system <NUM> coupled to the base section <NUM>. In some embodiments, braces <NUM> may be coupled to the frame <NUM> substantially aligned with the indoor heat exchanger <NUM> to provide mounting points for other components of the mobile section <NUM>, such as the air return <NUM>, as shown in <FIG> and <FIG>. A panel <NUM> may be coupled to the frame <NUM> and may be arranged to cover a side of the housing <NUM> and form part of the plenum <NUM> with the ECU <NUM> in the expanded-use position. In some embodiments, the panel <NUM> may be flexible and held in place relative to the housing <NUM> using complementary magnetic strips or strips of hook and loop material along the perimeter of the panel <NUM>.

In the illustrative embodiment, the air return <NUM> may include a blower unit <NUM> coupled to an extendable strut <NUM>, and a flexible shroud <NUM> coupled to the blower unit <NUM> and to the frame <NUM> of the carriage <NUM> to define the plenum <NUM> as shown in <FIG> and <FIG>. The strut <NUM> allows selective movement of the blower unit <NUM> between a retracted position, shown in <FIG>, and an extended position, shown in <FIG>, relative to the carriage <NUM>. The flexible shroud <NUM> moves with the blower unit <NUM> as suggested in <FIG>.

The extendable strut <NUM> may include a pair of spaced apart brackets <NUM> and corresponding pairs of slide mechanisms <NUM>, <NUM> coupled to the brackets <NUM> as shown in <FIG>. The blower unit <NUM> may be coupled to the slide mechanisms <NUM>, <NUM> for mrelative to the brackets <NUM>. In some embodiments, the slide mechanisms <NUM>, <NUM> may be arranged similar to the slide mechanisms <NUM>, <NUM> and have interfacing rail members that allow substantially linear movement of the blower unit <NUM> relative to the brackets <NUM>. The brackets <NUM> may be coupled to the braces <NUM> of the carriage <NUM>.

As shown in <FIG>, a latch <NUM> of the strut <NUM> may control movement of the blower unit <NUM> between the extended and retracted positions. The latch <NUM> may be mounted for rotation about a pivot <NUM>, such as a fastener, between a stay position, shown in <FIG> and <FIG>, and a release position, shown in <FIG> and <FIG>. Tabs <NUM> may extend laterally from the latch <NUM> to engage with the slide mechanism <NUM> to block movement of the blower unit <NUM> with the latch <NUM> in the stay position. A user can move the latch <NUM> to the release positon and grab a strap or handle <NUM> coupled to the blower unit <NUM> to move the blower unit <NUM> to the extended position as suggested in <FIG>. The latch <NUM> is moved to the stay position to block movement of the blower unit <NUM> from the extended position toward the retracted position as shown in <FIG>. In some embodiments, a biasing element (not shown), such as a spring, can bias the latch <NUM> toward the stay position. In some embodiments, a coupling <NUM> may be formed on the blower unit <NUM> for attachment of a return conduit <NUM>. Various forms of attachment are possible, and the present invention is not limited to the coupling <NUM> shown.

In the illustrative embodiment, the air supply <NUM> may include a flexible shroud <NUM> coupled to the carriage <NUM>, a hanger <NUM> coupled to the shroud <NUM>, and a plurality of flaps <NUM>, <NUM>, <NUM> pivotally coupled to the carriage <NUM>. The air supply <NUM> may be movable between a flattened position, shown in <FIG> and <FIG>, to an erected position, shown in <FIG> and <FIG>. The flaps <NUM>, <NUM>, <NUM> are substantially rigid to provided support for the hanger <NUM> in the erected position. The shroud <NUM>, hanger <NUM>, and flaps <NUM>, <NUM>, <NUM> may extend along the carriage <NUM> in the flattened position and may extend away from the carriage <NUM> in the erected position. An exemplary process for moving the air supply <NUM> from the flattened position to the erected position is illustrated in <FIG>. With the mobile section <NUM> in the expanded-use position, the flaps <NUM>, <NUM>, <NUM> are pivoted away from the shroud <NUM> as suggested in <FIG>. The hanger <NUM> is moved away from the carriage <NUM> to extend the shroud <NUM> and define the plenum <NUM> as suggested in <FIG> and <FIG>. The flaps <NUM>, <NUM> are pivoted toward the shroud <NUM> and the hanger <NUM> is mounted on the flaps <NUM>, <NUM> as suggested in <FIG>. The flap <NUM> is pivoted toward the flaps <NUM>, <NUM> as suggested in <FIG>. In some embodiments, the flap <NUM> may engage with the flaps <NUM>, <NUM> and may be secured with one or more fasteners to block the hanger <NUM> from being removed from the flaps <NUM>, <NUM> and to block the flaps <NUM>, <NUM> from pivoting away from the hanger <NUM>. In some embodiments, a coupling may be formed on the hanger <NUM> for attachment of a supply conduit <NUM>. Various forms of attachment may be possible, and the present disclosure is not limited to any particular coupling.

As shown in <FIG>, a control module <NUM> may be coupled to the base section <NUM>. The exemplary control module <NUM> includes a controller <NUM> mounted in a case <NUM>. The controller <NUM> may be configured to control operation of the ECU <NUM>. A user interface <NUM> may be arranged on the case <NUM> and may be accessible through the housing <NUM> of the base section <NUM> to allow a user to operate the ECU <NUM>. A power cable <NUM> can be stored within the base section <NUM> during transport and removed to connect the control module <NUM> with a power source, such as a generator. In some embodiments, the case <NUM> may be pivotally coupled to the housing <NUM> by a hinge <NUM> to allow the control module <NUM> to be moved to a raised position as shown in <FIG>, such as for service or maintenance. In some embodiments, a latch <NUM> coupled to the case <NUM> may be configured to slide relative to the case <NUM> and engage with the housing <NUM> to hold the control module <NUM> in the raised position. In some embodiments, a heater <NUM> may be coupled to the carriage <NUM>.

In the illustrative embodiment, a brace <NUM> may be coupled to the mobile section <NUM> as shown in <FIG>. The exemplary brace <NUM> includes an arm <NUM> coupled to the carriage <NUM> by a pivot <NUM>, such as a fastener, for rotation about the pivot <NUM> relative to the carriage <NUM>. The arm <NUM> defines a distal end <NUM> extending away from the base section <NUM> and a proximal end <NUM> arranged toward the base section <NUM>. One or more pins <NUM> are coupled to the carriage <NUM> and extend through the arm <NUM>. The pins <NUM> engage with the arm <NUM> to limit pivoting and lateral movement of the arm <NUM>. The arm <NUM> is movable between an unlocked position, shown in <FIG>, and a locked position, shown in <FIG>. In the unlocked position, the proximal end <NUM> of the arm <NUM> is spaced apart from the platform <NUM> of the housing <NUM> to allow movement of the mobile section <NUM> from the expanded-use position toward the collapsed-storage position. In the locked position, the proximal end <NUM> of the arm <NUM> engages with the platform <NUM> to block movement of the mobile section <NUM> from the expanded-use position toward the collapsed-storage position. The brace <NUM> also limits bending loads placed on the slide mechanisms <NUM>, <NUM>. The arm <NUM> engages with the platform <NUM> in the locked position and the pins <NUM> engage with the arm <NUM> and the carriage <NUM> to distribute at least a portion of the load on the slide mechanisms <NUM>, <NUM> from the mass of the mobile section <NUM> through the arm <NUM> to the platform <NUM>. A biasing member, such as a spring, is coupled to the carriage <NUM> and the arm <NUM> to bias the arm <NUM> toward the locked position. A user can engage with the distal end <NUM> of the arm <NUM>, such as by stepping on the distal end <NUM>, to move the arm <NUM> to the unlocked position and allow movement of the mobile section <NUM> from the expanded-use position toward the collapsed-storage position.

An exemplary process for moving the ECU <NUM> from the collapsed-storage position to the expanded-use position is illustrated in <FIG> and <FIG>. The fan unit <NUM> of the fan assembly <NUM> is moved from the inboard position, shown in <FIG>, to the outboard position, shown in <FIG>. The carriage <NUM> of the mobile section <NUM> is moved from the stowed position to the deployed position, as suggested in <FIG>, to define the plenum <NUM> of the housing <NUM>. The air return <NUM> is moved from the retracted position to the extended position to define the plenum <NUM>, as suggested in <FIG>, and the air supply <NUM> is moved from the flattened position to the erected position to define the plenum <NUM>, as suggested in <FIG>.

The exemplary expandable ECU <NUM> allows for large outdoor heat exchangers and indoor heat exchangers to be used, thereby maximizing efficiency and capacity of the temperature control system <NUM> and minimizing energy and fuel consumption. The ECU <NUM> also minimizes the footprint required for transport and storage. The ECU <NUM> provides separate large plenums for airflow through the outdoor heat exchangers and indoor heat exchangers, further maximizing capacity and efficiency of the temperature control system <NUM>. The arrangement of the base section <NUM> and mobile section <NUM> allow for easy access to and replacement of components. Use of various materials for the components in the ECU <NUM> are contemplated by the present invention, such as metals, plastics, fabrics, sheets, and films.

Claim 1:
An environmental control unit (<NUM>) comprising:
a base section (<NUM>);
a mobile section (<NUM>) coupled to the base section (<NUM>) for movement between a collapsed-storage position arranged substantially within the base section (<NUM>) and an expanded-use position extending from the base section (<NUM>), to allow separate air flows through the base section (<NUM>) and the mobile section (<NUM>) during operation of the environmental control unit (<NUM>); and
a temperature control system (<NUM>) coupled to the base section (<NUM>) and the mobile section (<NUM>), the temperature control system (<NUM>) configured to selectively heat or cool air flowing through the mobile section (<NUM>),
wherein an indoor heat exchanger (<NUM>) of the temperature control system (<NUM>) is coupled to the mobile section (<NUM>) and an outdoor heat exchanger (<NUM>, <NUM>) of the temperature control system (<NUM>) is coupled to the base section (<NUM>), and the indoor heat exchanger (<NUM>) is arranged for movement with the mobile section (<NUM>) relative to the outdoor heat exchanger (<NUM>, <NUM>) and/or
wherein the environmental control unit (<NUM>) is arranged within a first footprint in the collapsed-storage position, and the environmental control unit (<NUM>) is arranged within a larger second footprint in the expanded-use position,
and wherein
the mobile section (<NUM>) and the temperature control system (<NUM>) are contained within the base section (<NUM>) in the collapsed-storage position.