Note: Descriptions are shown in the official language in which they were submitted.
CA 02810306 2013-03-26
THERMOELECTRICALLY AIR CONDITIONED TRANSIT CASE
CROSS-REFERENCE APPLICATION
[0001] This application is a divisional of Canadian patent application number
2,617,895 filed December 2, 2005.
FIELD OF THE INVENTION
[0002] This invention relates generally to thermoelectrically air conditioned
cases.
More specifically, the present invention relates to thermoelectric air
conditioners for use
with, and mounted on or in, a transit case for maintaining a desired air
temperature within the
transit case to protect temperature sensitive equipment, such as electrical
and electronic
devices.
BACKGROUND
[0003] Transit cases exist to house and protect equipment during shipment from
one
location to another location and during temporary use of the equipment at
remote locations.
These transit cases are also sometimes referred to by other and different
names, such as:
Transit Case; Dry Case; Rotomold Case; Rotomolded Case; Rotationally Molded
Case;
Injection Molded Case; Utility Case; Transport Case; Transportation Case;
Travel Case;
Rack Case; Rackmount Case; Shock-Rack Case; Blow Molded Case; Vacuum Molded
Case;
Shipping Case; Storage Case; Military Case; Waterproof Case; Engineered Case;
Computer
Case; and ATA (Airline Travel) Case.
[0004] These cases are typically produced of the following materials:
Rotomolded PE
(polyethylene); Injection molded ABS; Fiberglass (FRP); Thermo Stamped
Composite
(TSC), which is glass-reinforced polypropylene; Aluminum; Steel; Stainless
Steel, and other
materials.
[0005] These cases are manufactured by a number of different firms. A few of
the
manufacturers in this industry include: Hardigg Industries, Inc., South
Deerfield, MA (see
www.hardigg.com); ECS Composites Inc., Grants Pass, OR (see
wvvvv.ecscase.com); SKB
Corp., Orange, CA (see www.skbcases.com); Zero Manufacturing Inc., North Salt
Lake, UT
(see www.zerocases.com); Pelican Products, Inc., Torrance, CA (see
vvww.pelican.com);
Quantum Scientific, Ontario, Canada (see www.cyber-case.com); Ameripack
Corporation,
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Robbinsvil le, NJ (see www.ameripack.com).
[0006] These cases are designed to house and protect equipment. The equipment
can
include items such as electronics, instrumentation, computers,
telecommunications gear, and
the like. Protection is provided during transit, storage and operation of the
equipment. The
cases are typically designed to protect the equipment contained within the
case from one or
more of the following elements (list is not all-inclusive): heat; dirt; dust;
debris; vandalism;
shock; vibration; dropping; moisture; rain; snow; sleet; hail; ice; cold; and
the like.
[0007] Depending on the style and construction of the case, many cases can
handle
one or more of the above needs. But, most, if not all, have difficulty
handling heating and
cooling requirements of the internal equipment during transportation, storage,
and operation.
Since most cases are airtight (or substantially airtight), if electronics are
contained within the
case, there is often heat build-up. Also, if the case is outdoors, and
especially if the case is
outdoors and in direct sunlight, heat build-up can be excessive, causing
damage or failure to
the equipment within the case.
[0008] Conventional solutions to the above heat problem include fans, holes,
openings, louvers, etc. in or on the case. These solutions to the heat
problem, however, then
cause the case to give up its ability to protect against other elements, such
as dirt, dust, other
contaminants, etc. In addition, these solutions cannot drive the temperature
within the case
below ambient.
[0009] Another conventional solution is to install a heat exchanger in or on
the case.
But conventional heat exchangers cannot drive the temperature within the case
below
ambient.
[0010] If the goal is to drive the temperature within the case below the
ambient
temperature, this can best be done utilizing an air conditioner. Most air
conditioners are the
traditional compressor-based type. Since traditional compressor-based air
conditioners have a
compressor, they are somewhat larger in size and heavier in weight than
desired. In addition,
traditional compressor-based type air conditioners must remain in one
orientation (typically
vertical). Also, compressor-based air conditioners include additional
components, such as
refrigerants and filters, and require regular maintenance. Further, most
compressor-based
coolers are AC-powered (120VAC or 240VAC), are not easily or readily portable,
and have
other disadvantages when considered for use with a transit case.
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SUMMARY
[0011] The present invention is directed to systems and methods for
maintaining a
desired air temperature within a portable case, such as a transit case, using
a thermoelectric
heat exchanger.
[0012] According to one preferred embodiment of the present invention, a
thermoelectric air conditioner is mounted on or in a transit case for cooling
the contents
(typically sensitive equipment or systems) within the transit case.
[0013] According to another aspect of the invention, a light-weight and
compact
thermoelectric air conditioner is used. A thermoelectric solid state air
conditioner provides
advantages over conventional compressor-type air conditioners in that a
thermoelectric air
conditioner has no compressor, refrigerants or filters and provides reliable,
virtually
maintenance-free cooling in both indoor and outdoor applications.
[0014] According to another aspect of the invention, the thermoelectric air
conditioner is incorporated into the case, concealed within the housing and/or
cover of the
transit case. In this embodiment, the thermoelectric air conditioner is
protected by the design
of the case, the mounting arrangement, the shock-mounted frame, etc.
[0015] According to another aspect of the invention, the thermoelectric air
conditioner is mounted partially internal and partially external to the
transit case.
[0016] According to another aspect of the invention, the thermoelectric air
conditioner is mounted to the top and/or side of the transit case.
[0017] According to another aspect of the invention, more than one
thermoelectric air
conditioner are installed in or on the case.
[0018] According to another aspect of the invention, insulation is installed
within the
transit case. Insulation reduces thermal heat transfer between the interior
and the exterior of
the case. The addition of insulation can also reduce solar loading on the case
and heat
penetration into the case, providing for greater reduction of internal
temperatures.
[0019] According to another aspect of the invention, an adapter plate can be
used to
"close the gap" between the edges of the thermoelectric air conditioner
mounting flange and
the internal sides of the transit case. The adapter plate preferably includes
a seal or gasket
that forms a boundary between the thermoelectric air conditioner and the case.
This further
enhances the ability of the transit case to maintain, as close as possible, an
airtight status and
seal out moisture, dirt, sand, etc. thus substantially preventing these
contaminants from
entering the interior of the case.
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[0020] According to another aspect of the invention, an extender piece or
extension
frame can be used to flush mount the thermoelectric air conditioner to the
case when, for
example, the entire internal cavity of the case is needed to house the
equipment.
[0021] According to another aspect of the invention, the thermoelectric air
conditioner is removably mounted on the case such that it can be mounted on
the case during
operation or stowed away in the case during transit.
[0022] According to another aspect of the invention, the thermoelectric air
conditioner is housed within a secondary case and the equipment is housed
within a primary
case. .During operation, the covers of the primary and secondary cases are
removed such that
the primary and secondary cases can be connected and can be in thermal
communication.
During transit, the primary and secondary cases can be disconnected and the
covers can be
replaced such that the equipment and thermoelectric air conditioners are
protected. In one
embodiment, the primary case and the secondary case are mounted end to end,
and in another
embodiment the primary case and the secondary case are mounted one on top of
the other.
[0023] According to another aspect of the invention, a rack mounted frame can
be
installed in the cavity of the case. In this embodiment, the equipment and
thermoelectric air
conditioners can be mounted on the rack mount frame to balance the load on the
frame and
make it easier to handle the case. In addition, the rack mount frame can be
supported by
elastomer shock mounts attached to the walls of the case to protect the
equipment mounted in
the case and help absorb shock, vibration, noise, etc.
[0024] According to another aspect of the invention, the thermoelectrically
air
conditioned transit case is designed for easy handling. In one embodiment, the
case is fitted
with wheels so that the case may be easily moved around. In another
embodiment, the
thermoelectrically air conditioned transit case is fitted with handles that
are located in
grooves or recesses in the housing and are positioned within the groove or
recess when not in
use and are accessible or capable of moving out of the groove or recess when
in use. In
another embodiment, the thermoelectrically air conditioned transit cases may
be stacked end-
to-end and/or one on top of another. In this embodiment, the housing of the
case may include
a shoulder and slot design wherein the shoulder of one case would be received
within a
corresponding slot of an adjoining case.
[0025] Additional features and advantages of the invention will be made
apparent
from the following detailed description of illustrative embodiments that
proceeds with
reference to the accompanying drawings.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The invention is best understood from the following detailed
description when
read in connection with the accompanying drawing. It is emphasized that,
according to
common practice, various features of the drawings are not to scale. On the
contrary, the
dimensions of various features are arbitrarily expanded or reduced for
clarity. Included in the
drawings are the following Figures that show various exemplary embodiments and
various
features of the present invention:
[0027] Figure 1 shows a perspective view of an exemplary thermoelectrically
air
conditioned transit case having a thermoelectric air conditioner vertically
mounted internal to
the transit case with the transit case front cover removed for clarity;
[0028] Figure 2 is a side view of the thermoelectrically air conditioned
transit case of
Figure 1;
[0029] Figure 3 is an end view of the thermoelectrically air conditioned
transit case of
Figure 2;
[0030] Figure 4 is an exploded view of the exemplary thermoelectrically air
conditioned transit case of Figure 1;
[0031] Figure 5 shows a perspective view of another exemplary embodiment of a
thermoelectrically air conditioned transit case having the thermoelectric air
conditioner
horizontally mounted internal to the transit case with the transit case top
cover opened for
clarity;
[0032] Figure 6 is an exploded view of the exemplary thermoelectrically air
conditioned transit case similar to the embodiment of Figure 5;
[0033] Figure 7A is a perspective view of another exemplary embodiment of a
thermoelectrically air conditioned transit case having a thermoelectric air
conditioner
through-mounted with at least a portion of the thermoelectric air conditioner
being internal to
the transit case;
[0034] Figure 7B is a perspective view of the embodiment of Figure 7A with the
thermoelectric air conditioner flush-mounted to the case;
[0035] Figure 8 is a perspective view of another exemplary embodiment of a
thermoelectrically air conditioned transit case having an external,
horizontal, through-
mounted thermoelectric air conditioner;
[0036] Figure 9A is an exploded view of an exemplary thermoelectrically air
conditioned transit case similar to the embodiment of Figure 7A, wherein the
thermoelectric
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air conditioner is removably mounted;
100371 Figure 9B shows the thermoelectric air conditioner of Figure 9A removed
and
stowed in the transit case;
100381 Figures 10A-10D show features of another exemplary thermoelectric air
conditioned transit case;
[0039] Figure 11 is a perspective view of another exemplary embodiment of a
thermoelectric air conditioned transit case having a protective, secondary lid
for covering and
protecting the thermoelectric air conditioner during transit;
[0040] Figures 12A and 12B are an exploded perspective view of another
exemplary
embodiment of a thermoelectric air conditioned transit case having an extender
piece for
mounting the thermoelectric air conditioner to the transit case;
[0041] Figures 13A and 13B is an exploded perspective view of another
exemplary
embodiment of a thermoelectric air conditioned transit case having two cases
mounted to one
another one, with the thermoelectric air conditioner mounted in a secondary
case and the
equipment to be protected in the primary case;
[0042] Figure 14 is a chart illustrating exemplary design or performance
standards for
an exemplary transit case;
[0043] Figure 15 is a perspective view of an exemplary thermoelectric air
conditioner
in accordance with the present invention;
[0044] Figure 16 is a cross sectional view of the thermoelectric air
conditioner of
Figure 15;
[0045] Figure 17 is an exploded perspective view of the thermoelectric air
conditioner
of Figure 15;
[00461 Figure 18 is an exploded perspective view of an exemplary heat
exchanger in
accordance with the present invention;
[0047] Figure 19 shows an exemplary heat sink with slotted fins for use with
the
thermoelectric air conditioner;
[0048] Figure 20a shows an exemplary "cold side" cover of the thermoelectric
air
conditioner having a built-in condensate drip pan and Figure 20b shows another
exemplary
condensate drip pan; and
[0049] Figures 21A-21F show features of another exemplary thermoelectrically
air
conditioned transit case.
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DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0050] The present invention is directed to systems and methods for
maintaining a
desired temperature within a portable case 2, such as a transit case, using a
thermoelectric
heat exchanger 7. In a preferred embodiment, one or more thermoelectric air
conditioners 7 is
mounted on or in a transit case 2 for cooling the contents (typically
sensitive equipment
and/or systems) within the transit case 2. A properly sized thermoelectric air
conditioner 7 is
capable of reducing the temperature inside the case 2 below the ambient
temperature outside
the case 2, thus providing a temperature inside the case 2 that is within the
customer's goals
and ensuring safe storage and/or operation of equipment.
[0051] At the same time, a thermoelectrically air conditioned transit case 1
preferably
maintains most, if not all, of the benefits of using a transit case 2 (i.e.,
light-weight, mobile,
stackable, durable, protective, etc.) to transport equipment from one location
to another
location. Also, a thermoelectric air conditioner 7, as a solid-state device to
control
temperature, provides other benefits, including: highly reliable; virtually
maintenance-free;
no air exchange between outside and inside; suitable for use in operating
environment up to
about 140 F; indoor or outdoor use; vertical or horizontal installation;
compact; light-weight;
wide capacity range (e.g., about 200-2500 BTU range); cooling and/or heating
models; no
filters to change or clean; no compressor; no condenser; no refrigerants; no
chemicals; no
copper tubing; no moving components (other than fans); ideal for cooling
electronics; no
performance loss when input voltage drops or there are "brown-outs"; units are
manufactured
to UL standards; thermoelectric coolers can be conveniently powered from AC
and/or DC
power sources; and the like.
[0052] The thermoelectrically air conditioned transit case 1 includes several
exemplary embodiments. Figures 1-6 show exemplary internal embodiments of
thermoelectrically air conditioned transit cases 1 having the thermoelectric
air conditioner 7
located internally within the transit case 2. In the exemplary internal
embodiments shown in
Figures 1-6, the thermoelectric air conditioner 7 is preferably mounted
completely within an
outer boundary (walls, covers, lids, etc.) of the case 2 and is completely
protected by the
transit case 2.
10053] In exemplary external embodiments shown in Figures 7-10, a
thermoelectric
air conditioner 7 is located externally on the transit case 2. Figure 7A shows
an externally
mounted thermoelectric air conditioner 7 wherein the thermoelectric air
conditioner 7 is
through-mounted on the transit case 2. In the through-mounted embodiment, the
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CA 02810306 2013-03-26
thermoelectric air conditioner is located partially internal and partially
external to the transit
case 2 (i.e., partially inside and partially outside the outer boundary of the
transit case).
100541 In, the exemplary external embodiment shown in Figure 7B, the
externally
mounted thermoelectric air conditioner 7 is flush-mounted outside the outer
boundary (walls,
covers, lids, etc.) and does not penetrate into the interior cavity 14 of the
case 2. An
extension frame 37 is used to flush-mount the thermoelectric air conditioner 7
to the case 2
and the extension frame 37 extends between the mounting flange 73 of the
thermoelectric air
conditioner's mounting frame 72 and the exterior surface of the case 2 around
the periphery
of the opening 15 in the case 2. This embodiment can be used where there is
little or no room
unoccupied by the equipment 5 within the internal cavity 14. The cold side 76
of the
thermoelectric air conditioner 7 is in thermal communication with the internal
cavity 14 of
the transit case 2 through an opening and/or passageway 15 in the wall 10 of
the case 2. The
external, flush-mounted thermoelectric air conditioner 7 can be protected by a
separate lid or
cover 25 (see, for example, Figure 11).
[0055] Figure 8 shows another embodiment of a transit case 2 having end covers
20
and the thermoelectric air conditioner 7 is externally mounted to the top of
the case 2. This
embodiment may include a through-mounted and/or a flush-mounted thermoelectric
air
conditioner 7 and allows for easy access to the internal cavity 14 and the
equipment 5 stored
therein from one or either end of the case 2. Preferably, the external, top
mounted
thermoelectric air conditioner 7 is removable or protected by a separate lid
or cover 25
during transit.
[0056] The embodiment of Figures 9A and 9B show an externally mounted
thermoelectric air conditioner 7 that is removably-mounted to the case 2. As
shown, the
thermoelectric air conditioner 7 can be removably-mounted directly to the case
2, to a cover
or lid 20 of the case 2. Alternatively, the thermoelectric air conditioner 7
can be removably-
mounted to a separate, secondary cover or lid 24 (see Figure 10C). As shown in
Figure 9A,
the thermoelectric air conditioner 7 is installed in or on the transit case 2
to control the
temperature of the internal cavity 14 of the case 2 during operation. During
transit, the
thermoelectric air conditioner 7 can be removed and stored within the transit
case 2, as
shown in Figure 9B.
[0057] In another embodiment shown in Figures 10A-10D, the removable
thermoelectric air conditioner 7 can be pre-mounted to a separate, secondary
cover/lid 24 that
can be stored in a separate, secondary case 2b during transit, and placed on
the primary case
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2a to be cooled after transit. Figure 10A shows the primary case 2a (i.e., the
case housing the
equipment 5 to be cooled) ready for transit. Figure 10B shows the secondary
case 2b (i.e., the
case housing the thermoelectric air conditioner 7 mounted to a secondary cover
24) ready for
transit. Figure 10C shows the secondary case 2b with its cover 20b open and
the
thermoelectric air conditioner 7 mounted to secondary cover 24 being removed.
Although not
shown, it is also
contemplated that a complete case 2a (including the entire housing 3a, cover
20a, and
mounted thermoelectric air conditioner 7) could be stowed within another,
larger case 2b for
transit. Figure 10D shows the primary case 2a on-site, its transit cover 20a
removed and the
combination thermoelectric air conditioner 7 and secondary cover 24
installed/mounted to
the lower portion of the primary case 2a. The thermoelectrically air
conditioned transit case 1
can now be placed in operation. The pre-mounting of the thermoelectric air
conditioner 7 to a
secondary cover 24 that is the same as the cover 20a used during transit of
the primary case
2a allows for easy change-over from the transit mode to the operational mode
because the
secondary cover 24 preferably has the same dimensions, mating surface 46, and
closure
system 95 as the cover 20a used during transit.
[0058] The externally mounted thermoelectric air conditioner 7 embodiments may
also include a separate cover/lid 25 to cover the exposed portion of the
thermoelectric air
conditioner 7. For example, in the exemplary through-mounted embodiment shown
in Figure
11, the cold side 76 of the thermoelectric air conditioner 7 extends through
an opening 15 in
the case wall 10 and hence is located and protected within the outer boundary
of the transit
case 2. The hot side 77 of the thermoelectric air conditioner 7 is outside the
outer boundary.
The hot side 77 of the thermoelectric air conditioner 7 in this embodiment may
be protected
by a separate, secondary cover/lid 25. A secondary cover/lid 25 may also be
used with an
external, flush-mounted embodiment.
100591 The embodiment of Figure 12A and 12B includes a thermoelectric air
conditioner 7 mounted to a transit case 2a using an extender piece 37 (i.e.,
an
adapter/spacer/extension section). This transit case extender piece 37 is
designed to attach to
the primary transit case 2a in place of one of the primary transit case 2a
covers/lids 20a and
provide temperature control within the internal cavity 14a of the primary case
2a, in which
the equipment 5 is housed.
100601 Figure 12A shows a thermoelectric air conditioner 7 mounted in a
transit case
extender piece 37 that is mounted vertically to the end of the primary transit
case 2.
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Preferably, a sealing gasket 81 is disposed between the mounting flange 73 of
the
thermoelectric air conditioner 7 and the mounting flange 38 of the extender
piece 37.
Preferably, the existing closure system 95 (as shown latches 96) of the
primary case 2a are
used to engage corresponding closure mechanism 95 on the extender piece 37 to
hold the
extender piece 37 to the primary case 2a.
[0061] As shown in Figure 12B, separate covers 25 may be attached to the ends
of the
transit case extender piece 37 to protect the thermoelectric air conditioner 7
during transport
or storage. Alternatively, the transit case extender 37 can be left attached
to the primary case
2a with a cover 25 added to protect the thermoelectric air conditioner 7
during transport and
storage.
[0062] Alternatively, the thermoelectric air conditioner 7 and extender piece
37 can
be mounted horizontally to the top of the primary transit case 2a (similar to
the embodiment
shown in Figures 13A and 13B). A separate cover 25 may then be attached to the
top of the
transit case extender piece 37 to protect the thermoelectric air conditioner 7
during transport
or storage.
[0063] In another embodiment shown in Figure 13A, the thermoelectric air
conditioner 7 may be located in a separate, secondary case 2b during transit
that can be
connected to the case 2a housing the equipment 5 to be protected during
operation.
Preferably, a sealing gasket 81 is disposed between the mounting flange 73 of
the
thermoelectric air conditioner 7 and the mounting flange 68 of the secondary
case 2b.
Preferably, the existing closure system 95 (as shown latches 96) of the
primary case 2a are
used to engage a corresponding closure mechanism 95 on the secondary case 2b
to hold the
secondary case 2b to the primary case 2a.
[0064] The secondary case 2b housing the thermoelectric air conditioner 7 may
be
connected ¨ one on top of the other (as shown in Figure 13A) or end-to-end
(similar to the
extender piece embodiment shown in Figure 12A) ¨ to the primary case 2a
housing the
equipment 5 and then placed in-service to control the temperature of the
internal cavity 14a
of the primary case 2a to protect the equipment 5 housed therein. In use, the
cold side 76 of
the thermoelectric air conditioner 7 in the secondary case 2b is in thermal
communication
with the internal cavity 14a of the primary case 2a. As shown in Figure 13B,
removable
covers 25 may be attached to the corresponding mating ends of the primary 2a
and secondary
transit cases 2b to protect the thermoelectric air conditioner 7 during
transport or storage.
[0065] In addition, the thermoelectric air conditioner 7 can be mounted in
either a
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vertical or horizontal orientation. For example, in the illustrated
embodiments of Figures 1-4,
I2A, and 12B, the thermoelectric air conditioner 7 is mounted vertically
proximate an
opening 15 at one end/side of the case 2. In the embodiments of Figures 5-11,
13A, and 13B,
the thermoelectric air conditioner 7 is mounted horizontally proximate an
opening 15 in the
top of the case 2.
[0066] It is also contemplated that more than one thermoelectric air
conditioner 7 can
be mounted in or on a transit case 2. For example, for a transit case 2 having
front and rear
covers 20, such as Figures 1-4 and 21A-21F, one thermoelectric air conditioner
7 could be
mounted in or on the front opening 15 and a second thermoelectric air
conditioner 7 could be
mounted in or on the rear opening 15. Further, one thermoelectric air
conditioner 7 could be
top mounted while a second-thermoelectric air conditioner 7 could be end
mounted.
[0067] The thermoelectrically air conditioned transit case 1 houses and
protects
sensitive equipment 5 contained within the case 2 during transit (i.e.,
shipment from one
location to another location) and during use of the equipment 5 at remote
locations. The
thermoelectrically air conditioned transit case 1 includes a durable case 2 or
housing coupled
with a thermoelectric air conditioner 7 and is designed to protect sensitive
equipment 5 stored
therein from environmental conditions, including for example extreme
temperature.
Preferably, the thermoelectrically air conditioned transit case 1 is also
constructed to be
contaminant-tight (e.g., airtight, watertight, and dustproof) and to protect
the equipment 5
from other environmental conditions including impact, shock, vibration,
vandalism, and
contaminants ¨such as air, water, moisture, humidity, dirt, dust, debris,
chemicals, etc. The
thermoelectric air conditioner 7 is capable of driving the temperature inside
the transit case to
a temperature below ambient.
[0068] The thermoelectrically air conditioned transit case 1 is designed to
protect
sensitive equipment and/or systems from the rigors of: commercial and
industrial use; air,
land, and sea shipment; temporary storage; worldwide military deployment;
movements
between remote locations; use at remote locations; and the like. Preferably
the
thermoelectrically air conditioned transit case 1 also enhances handling and
the overall
portability of the application, as explained more fully below.
100691 Transit cases are known by various names. As used herein, the term
transit
case includes portable cases used to house, store, ship, transport; and
protect equipment
and/or systems in transits from one location to another location or as the
equipment/system is
used at a remote location. The thermoelectrically air conditioned transit case
1 is designed-11-
CA 02810306 2013-03-26
and constructed to protect temperature sensitive equipment and/or systems.
Temperature
sensitive equipment and/or systems include, for example, electrical,
electronics, computer,
server, weapons, mobile command and control, deployed air traffic control,
surveillance,
global positioning, instrumentation, communication, and the like.
100701 Transit cases are manufactured by various manufacturers and come in a
variety of styles, sizes, and shapes. In addition, the thermoelectric air
conditioner 7 also
comes in a variety of capacities to handle different loads and sizes of
transit cases. The
present invention contemplates the refabrication/retrofitting of existing
transit cases 2 to
include a thermoelectric air conditioner 7, as well as implementation and
installation of the
thermoelectric air conditioner 7 during, or as part of, the original
manufacturing of the transit
case 2.
100711 The thermoelectrically air conditioned transit case 1 includes a
portable
protective housing 3 that is preferably light-weight, simple to design, rugged
in construction,
and economical to manufacture. Preferred material characteristics of the case
include: high
performance, impact-resistant, corrosion-resistant, UV-resistant, temperature-
resistant, water-
resistant, strong, durable, and the like. Suitable case materials include:
Thermo Stamped
Composite or TSC, which is glass-reinforced polyethylene, Rotomolded PE
(polyethylene),
injection molded ABS, Fiberglass (FRP), polyethylene for high impact strength,
high impact
structural copolymer, plastic, aluminum, plywood, canvas, nylon, leather,
denim, polyester,
light-weight metals, and other materials. Exemplary manufacturing techniques
include
rotational mold, injection mold, roto-mold, blow-mold, thermoformed processes,
welded
aluminum, drawn aluminum, and the like.
[0072j The case 2 of the thermoelectrically air conditioned transit case 1 can
be
manufactured as a standard case having standard dimensions and/or as a custom
case that is
manufactured to specific customer needs. For example, the case 2 can be
manufactured to fit
a particular payload and/or suite of equipment for a particular application,
such as
commercial, government, military, Homeland Security, etc.
[0073j Further, many military and defense customers require that cases meet
certain
design, environmental, and/or performance standards, such as MIL-STD-810
(shock, transit
drop, vibration, water-tight, etc.); MIL-STD-1472 (lift limitations, see
Figure 14); MIL C-
4150J; ATA (Air Transportation Association); loose cargo bounce; high/low
temperature
range; relative humidity; altitude, ultraviolet (UV) radiation; fungus; static
loading; and the
like. Preferably the design and construction of the thermoelectrically air
conditioned transit
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case I take these design parameters and limitations into consideration.
[0074] Preferably, the thermoelectrically air conditioned transit case 1 is
contaminant-tight (e.g., water-tight, air-tight, dust proof, etc.) when the
cover 20 (and/or
cover 25) is closed. Also, the interface between the thermoelectric air
conditioner 7 and the
transit case 2 is preferably contaminant-tight when the cover 20 of the
transit case 2 is open.
In addition, the interface between the hot side 77 and the cold side 76 of the
thermoelectric
air conditioner 7 is also preferably contaminant-tight.
[0075] The thermoelectrically air conditioned transit case 1 preferably
includes a case
closure system to close and seal any openings in the case 2. For example, the
case 2 closure
system can include one or more covers and/or lids 20, 25. Covers/lids 20, 25
are used to close
openings 15 in the case 2 used to, for example, allow access to the internal
cavity 14 of the
case 2 to load or access equipment 5. The covers/lids 20, 25 may be removably
or pivotally
mounted to the case 2. In embodiments having covers/lids 20, 25 pivotally
mounted to the
case, the covers/lids 20, 25 may be attached using one or more hinges 27.
[0076] In addition, the closure system preferably includes a closure mechanism
95,
such as one or more latches 96. Case closures 95 are preferably heavy-duty,
secure, strong,
and easy to operate. Types of suitable case closures 95 include twist latches,
"press and pull"
latches, etc. In an exemplary embodiment, the latch 96 imposes an impact
compressive force
to seal cover/lid 20, 25 to the enclosure opening 15 when the latch 96 is
closed. Preferably
the latches 96 are located in a cavity or recess 97 formed in the body of the
case 2 so the
latches 96 are not in the way during handling or shipping of the case 2.
[00771 Further, the case closure system can include a sealing system between
the
cover/lid 20, 25 and the case opening 15. For example, the sealing system can
include a
tongue 84 and groove 85 located around the perimeter of an opening 15 to seal
the cover/lid
20, 25 over the opening 15 when the case 2 closure is activated. The tongue 84
and
corresponding groove 85 are preferably located having one structure on the
case 2 and the
corresponding structure on the cover/lid 20, 25. In addition, a gasket 81 may
be used to seal
the connection of the cover/lid 20, 25 to the case opening 15.
[0078] Moreover, the case closure system can include a lock (not shown) for
securing
the cover/lid 20, 25 over the opening 15 in the case 2. The lock 98 may
include any
conventional locking mechanism and may be incorporated into the case 2 body or
be a
separate lock 98 that is independent from the case. The lock 98 helps deter
tampering, theft,
vandal ism etc.
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[0079] The portable thermoelectrically air conditioned transit case 1
preferably
includes a case handling system. In one embodiment, the case handling system
includes one
or more handles 91. Exemplary handles 91 include molded-in and/or hinged
designs and the
handles 91 may be sized and padded for comfort and ease of handling.
[0080] In another embodiment, the thermoelectrically air conditioned transit
case
can include wheels or casters 100 to further assist in the portability of the
case. The case can
also include a cargo handling system, such as slots 101 formed in the bottom
of the case to
accommodate the forks of a fork-lift machine, eye-bolts (not shown) on top of
the case to
accommodate a crane, and the like.
[0081] The case closure system and handling system are preferably located at
convenient locations on the housing and do not interfere with the operation,
storage, or
movement of the transit case. For example, preferably the latches 96, handles
91, etc. are
located in grooves 92 or recesses 97 in the housing 2 and are positioned
within the groove 92
or recess 97 when not in use and are accessible or capable of moving out of
the groove 92 or
recess 97 when in use. For example, the handles 91 can include swing-out
handles.
100821 In certain embodiments it may be desirable to store multiple
thermoelectrically air conditioned transit cases 1 together either end to end
or one on top of
another. For those embodiments it is preferred that the thermoelectrically air
conditioned
transit cases 1 are stackable. The thermoelectrically air conditioned transit
cases 1 may be
stacked end-to-end and/or one on top of another. As shown in Figure 10A, the
housing or
body 3a of the case 2a may include a shoulder 103 and slot 104 design wherein
the shoulder
103 of one case would be received within a corresponding slot 104 of an
adjoining case 2a.
In addition, an interlock system (not shown) can be used wherein adjoining
cases 2a could be
locked together during, for example, transit, storage, and/or use. The
interlocking system can
include latches, ties, tie-downs, straps, belts, bands, and the like.
[0083] The thermoelectrically air conditioned transit case 1 can also include
a
mounting system for mounting the thermoelectric air conditioner 7 within the
case. In one
preferred embodiment, the mounting system includes a rack-mount frame 40.
[0084] A rack-mount frame 40 is a supporting frame disposed within the housing
3
and spaced from the walls 10 and having an opening 42 on at least one side
facing an
opening 15 in the transit case 2 housing 3 for receiving the thermoelectric
air conditioner 7.
As shown in Figure 4, the thermoelectric air conditioner 7 includes a portion
(i.e., the "cold
side" 76) that can fit an opening 42 formed between the vertical rack rails 45
of the mounting
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frame 40 and the thermoelectric air conditioner 7 can be connected to the
mounting frame 40
of the rack rails 45. As shown in Figure 21C, the rack-mount frame 40 may also
be used to
hold other equipment, including the equipment 5 designed to be protected and
cooled by the
thermoelectric air conditioner 7.
[0085] In the rack-mount 40 thermoelectric air conditioner 7 embodiment, the
thermoelectric air conditioner 7 is mounted directly to the rack-mount frame
40 within the
internal cavity 14 of the transit case 2. The rack-mount frame 40 preferably
includes standard
mounting holes 41 and fasteners 43 for holding the thermoelectric air
conditioner 7 and/or
the equipment 5 in the rack 40. For example, the rack-mount frame 40 can be
designed in
accordance with EIA-RETMA standards for portable electronics and include
standard front
mounting holes 41 and locking clip-nut fasteners 43 for holding the equipment
5 in the rack
40.
[0086] The rack-mount frame 40 can include standard and custom rack-mounts.
Standard rack-mounts include 19-inch, 23-inch, and 24-inch rack-mounts. Also,
other
standard sizes, as well as, custom rack-mount cases having varying dimensions
can be used.
In other embodiments, the rack-mount frame 40 can include multiple, different
size racks,
custom racks, and/or adjustable mounting frames.
[0087] In addition, a separate, adapter plate 82 can be used to fill-in or
close the gap
between the thermoelectric air conditioner 7 and the internal sides of the
transit case 2. The
adapter plate 82 preferably includes a seal and/or gasket 81 that forms a
boundary between
the thermoelectric air conditioner 7 and the case 2. This further enhances the
ability of the
transit case 2 to maintain, as close as possible, an airtight status and seal
contaminants from
the interior 14 of the case 2. Further, the adapter plate 82 is preferably
insulated to improve
thermal efficiency.
[0088] The adapter plate 82 can extend around one or more sides of the
thermoelectric air conditioner 7. As shown in Figure 4, the adapter plate 82
extends across
and closes the gap between the top of the thermoelectric air conditioner 7 and
an interior
surface of the top of the case 2. In a preferred embodiment, the adapter plate
82 is a solid
piece to facilitate maintaining a contaminant-tight seal. Alternatively, the
adapter plate 82
can include one or more sealed exit ports 83, such as, for example, sealed
cable exits, sealed
control exits, and/or a sealed power receptacle. The adapter plate 82 can also
include one or
more controls 105 for controlling and monitoring an operation of the
thermoelectric device.
For example, a thermostat dial 105 can be provided on the adapter plate 82 for
setting an
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output temperature of the thermoelectric device.
[0089] Further, in certain embodiments where the thermoelectric air
conditioner 7 is
installed on one end of the internal rack-mount frame 40, a weight
distribution problem
might result. For example, consider an arrangement of mounting a
thermoelectric air
conditioner 7 in a transit case having a weight load of perhaps 60 lbs. on one
end of the
frame. If the end user were to install a minimal amount of electronics (i.e.,
5 lbs.) on the
other end of the rack 40, this could result in an unbalanced load and the
ruggedness and
protection level of the case 2 could be compromised in such a scenario.
However, the present
invention solves this problem by providing for the installation of internal
elastomer shocks
93 with different load ratings and/or additional shocks, thus balancing the
load on the frame
and taking into consideration the CG (center of gravity) of the load.
[0090] In other embodiments where impact sensitive equipment is stored within
the
case 2, the thermoelectrically air conditioned transit case I can include a
shock, vibration,
and/or noise mitigating system. In these impact sensitive embodiments, the
case is preferably
shock, vibration, and/or noise absorbing ("shock absorbing"). For example,
elastomer shock
mounts 93 can be used between the thermoelectric air conditioner 7 and the
case 2 to isolate
the thermoelectric air conditioner 7 and absorb any shock or vibration. In a
rack-mount 40
embodiment, shock mounts 93 can be located inside the case 2, for example,
between the
frame of the rack-mount frame 40 and the housing 3 of the case 2. This design
provides
protection to the thermoelectric air conditioner 7 and equipment 5 mounted to
the frame of
the rack-mount 40 housed within the case 2. Also, if the thermoelectrically
air conditioned
transit case 1 is made from a plastic material, the plastic material itself
can be shock
absorbing and the case absorbs some of the shock.
[0091] In addition, a cushioning system can be provided to further hold and
protect
the thermoelectric air conditioner and equipment 5 located within the
thermoelectrically air
conditioned transit case 1. For example, a customizable foam interior (not
shown) can be used
with the shape and amount of foam determined by the shape and the
characteristics of the
equipment 5 being protected. The cushioning system can be manufactured into
the case or
can be insertable. The cushioning system decelerates the equipment 5 in a
controlled manner
if the case is dropped or otherwise subjected to shock or vibration.
[0092] As shown in Figures 5, 7A, 7B, 1013, and 10C, the thermoelectrically
air
conditioned transit case 1 preferably includes a pressure relief valve 86 that
equalizes the
pressure inside and outside the case 2. In a more preferred embodiment, the
pressure relief
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valve 86 is an automatic pressure relief valve that automatically equalizes
the pressure. The
pressure relief valve 86 provides a watertight and airtight seal during
transit, such as air
travel where the thermoelectrically air conditioned transit case 1 experiences
varying
elevations, and thus pressures.
[0093] Figures 15-18 show an exemplary thermoelectric heat exchanger. The
thermoelectric heat exchanger in this case, a thermoelectric air conditioner 7
for cooling the
inside or internal cavity 14 of the case 2, includes one or more thermocouples
and at least one
heat sink 126, 128. The thermocouples are made from semiconductors and the
semiconductor
is heavily doped to create an excess (n-type) and a deficiency (p-type) of
electrons. The
junction between the n-type and the p-type is a semiconductor thermocouple. At
the cold side
76, energy (heat) is absorbed by electrons as they pass from a low energy
level in the p-type
semiconductor element, to a higher energy level in the n-type semiconductor
element. The
power supply provides the energy to move the electrons through the system. At
the hot side
77, energy is expelled to a heat sink 128 as electrons move from a high energy
level element
(n-type) to a lower energy level element (p-type). Heat absorbed at the cold
side 76 is
pumped to the hot side 77 at a rate proportional to current passing through
the circuit and the
number of couples.
[0094] These thermocouples, which can be connected in series electrically and
in
parallel thermally, are integrated into the thermoelectric air conditioner 7.
The thermoelectric
modules 141 are packaged between metallized ceramic plates. Thermoelectric
modules 141
can be mounted in parallel to increase the heat transfer effect or can be
stacked in multistage
cascades to achieve high differential temperatures. Solid state cooling is
relatively simple
compared to some of the classical techniques, such as using a compressor,
because there are
no moving parts (other than fans).
[0095] These thermoelectric devices have the capability to be either heating
systems
or cooling systems depending on the direction of the current. In addition, the
thermoelectric
devices can include embedded resistive heaters within the cold side in order
to effect heating
within the internal cavity 14. The following description focuses on a
thermoelectric heat
exchanger that is used for cooling, i.e., a thermoelectric air conditioner 7.
In the cooling
embodiment shown and described, the thermoelectric air conditioner 7 is
designed to exhaust
heat from inside the transit case 2 to outside the transit case 2 to protect
thermally sensitive
equipment 5 in the transit case 2.
100961 Unlike a conventional air conditioner, the thermoelectric air
conditioner 7
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used to cool equipment 5 within the transit case 2 is a solid state device and
has no
compressor, refrigerants or filters, and provides reliable, maintenance-free
cooling of the
interior (i.e., internal cavity) of the transit case 2.
[0097] Preferably the thermoelectrically air conditioned transit case 1 is
designed and
constructed to increase contaminant resistance (i.e., minimizing the transfer
of contaminants
from the hot side ¨ or outside of the transit case 2 ¨ to the cold side ¨ or
inside of the
transit case 2) and to improve thermal efficiency (i.e., minimize the transfer
of thermal
energy from the hot side ¨ or outside ¨ to the cold side ¨ or inside ¨ by
increasing
thermal isolation between the hot side and the cold side).
[0098] For example, the thermoelectric air conditioner 7 is preferably sealed
to be
contaminant-resistant and to minimize heat transfer between the hot side 77
and the cold side
76. Also, the connection between the thermoelectric air conditioner 7 and the
transit case 2 is
also preferably designed to be contaminant-resistant and to improve thermal
efficiency. In
addition, that transit case housing 3 and cover(s) 20, 25 are preferably
designed to be
contaminant-resistant and thermally efficient.
[0099] Contaminant-resistant means zero or substantially zero contaminants
will pass
between the hot side 77 and the cold side 76 of the thermoelectric air
conditioner 7 and/or
from the outside to the inside of the transit case 2. By making the
thermoelectrically air
conditioned transit case 1 contaminant-resistant, the long term reliability
and performance of
the equipment 5 stored in the transit case 2 may be improved by minimizing any
damage
from outside contaminants.
[0100] Thermal efficiency means reducing/minimizing thermal heat transfer from
the
hot side 77 to the cold side 76 of the thermoelectric air conditioner 7 and/or
from outside the
transit case 2 to inside the transit case 2. Thermal efficiency can be
increased by, for
example, using a reflective material on the outside of the case 2, using a UV
resistant
material for the case 2, using an insulating material around the inside of the
case 2, using an
insulating material at the connection between the thermoelectric air
conditioner 7 and the
case 2, and the like. Thermal efficiency can also be increased by designing
the system with
heat producing electrical components being mounted on a power pack heat sink
127, which
exhausts heat to the hot side 77 of the thermoelectric air conditioner 7.
Therefore, the heat
generated from the heat producing components is dissipated directly to the hot
side 77 of the
thermoelectric air conditioner 7.
[0101] Figures 15-18 show various features of an exemplary thermoelectric air
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conditioner 7. As shown, in Figure 15, the thermoelectric air conditioner 7
includes a housing
having a cold side cover 110 that covers the components on a cold side 76 of
the
thermoelectric air conditioner 7, a hot side cover 111 that covers the
components on a hot
side 77 of the thermoelectric air conditioner 7, and a mounting frame 72
positioned between
cold side cover 110 and hot side cover 111.
[0102] As shown, mounting frame 72 includes a mounting flange 73 formed over
the
outer periphery of at least two sides of mounting frame 72 and that extend
outside of the
housing. A plurality of through holes 74 are formed in mounting flange 73 for
mounting the
thermoelectric air conditioner 7 directly to the transit case 2 or to a
mounting frame 40 within
the transit case 2. In the embodiment shown, the mounting frame 72 also
includes a plurality
of through holes 113, corresponding to through holes 118, 135 in the cold side
cover 110 and
the hot side cover 111 for mounting both cold side cover 110 and hot side
cover 111 to
mounting frame 72.
[0103] Cold side cover 110 includes a substantially planar body 114 having
side walls
115 that define a cold side cavity 116. Opening 117 allows air to access the
cold side cavity
116.
[0104] As shown, a cold side fan 123 is mounted to cold side cover 110
proximate to
fan opening 122. Cold side fan 123 forces air through the fan opening 122,
across the cold
side 76 of the thermoelectric air conditioner 7, and out of the opening 117.
[0105] In a typical mounting to a transit case 2, cold side cover 110 extends
into or is
in thermal communication with the internal space 14 of the transit case 2 and
hot side cover
111 extends outside of or is in thermal communication with the outside of the
transit case 2.
[0106] As shown in Figure 15, the thermoelectric air conditioner 7 includes
one or
more controls, including a thermostat control knob 119 to allow an operator to
adjust the
temperature set-point of the thermoelectric air conditioner 7, a circuit
breaker 120 to trip the
device on, for example, an over-current condition, a power cord 121 for supply
power to the
device, and the like.
[0107] Figure 16 is a cross sectional view of an exemplary thermoelectric air
conditioner 7 showing a barrier 112 between the cold side 76 and the hot side
77. Power pack
heat sink 127 includes a base portion 163 having with a plurality of fins 164
extending from
one side of the base portion 163. Power pack heat sink 127 is mounted,
proximate to power
pack cutout 125, on the hot side 77 of mounting frame 72, with the base
portion 163
proximate to the mounting frame 72. Gasket 165 is attached to the cold side 76
of the
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mounting frame 72 proximate to the power pack cutout 125. Preferably, power
pack cover
158 is secured to gasket 165 with cover seal 167 proximate to the gasket 165.
Electrical
components 159, 160, 161, and 162 (159 and 161 not shown) are mounted to the
base portion
163 of the power pack heat sink 127 and protrude through power pack cutout 125
in
mounting frame 72 into a cavity 166. Mounting frame 72, gasket 165, and power
pack cover
158 define a non-planar barrier 112 between a cold side 76 and a hot side 77.
[0108] Figure 17 shows the interior of the housing of Figure 15. As shown in
Figure
17, the housing includes mounting frame 72, cold side cover 110, and hot side
cover 111. In
the embodiment shown, the mounting frame 72 includes two heat sink cutouts 124
and one
power pack cutout 125. Mounting frame 72 is located between the cold side 76
and the hot
side 77. The cold side 76 includes cold side heat sinks 126. Cold side heat
sinks 126 are
attached on the cold side 76 of mounting frame 72. The hot side 77 includes
power pack heat
sink 127 and at least one hot side heat sinks 128. Hot side heat sinks 128 are
attached on the
hot side of mounting frame 72. Power pack heat sink 127 is attached on the hot
side of
mounting frame 72.
[0109] Power supply assembly 129 may include power pack heat sink 127, and a
plurality of electrical components including, for example, a DC to DC active
power supply
159, one or more filter capacitors 160, a bridge rectifier 161, and a noise
suppression filter
162, and associated circuitry (not shown).
[0110] Hot side cover III includes a substantially planar body 130 having side
walls
131 that define a hot side cavity 132. Opening 133 allows air to access the
hot side cavity
132. Hot side cover 111 includes mounting brackets 134 that extend outward
from side walls
131. The mounting brackets 134 includes a plurality of through holes 135 for
receiving
fasteners (not shown) for mounting the hot side cover I 1 1 to the mounting
frame 72.
Mounting frame 72 includes through holes 113 corresponding to through holes
135 of hot
side cover 111. Fasteners (not shown) pass through holes 113 and through holes
135 to
secure hot side cover 111 to mounting frame 72.
[0111] The hot side includes one or more hot side fans 137 mounted proximate
fan
openings 136 in hot side cover 111. The hot side fans 137 draw air across the
power pack
heat sink 127 to remove heat and also force air through the fan openings 136,
across the hot
side 77 of the thermoelectric air conditioner 7, and out of the opening 133.
Hot side heat
sinks 128, (which are shown in Figure 18) are mounted to the hot side 77 of
mounting frame
72. Hot side fans 137 also draw air across hot side heat sinks 128 to expel
heat to the outside
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of the thermoelectric air conditioner 7.
[0112] A wire feed opening 140 is located in mounting frame 72 and provides
access
for running wires (not shown) between the hot side 77 and cold side 76. Wires
are disposed
through the wire feed opening 140 and sealed completely by a liquid tight
compression
fitting 139 disposed in wire feed opening 140. The liquid tight compression
fitting 139 may
increase thermal efficiency by preventing moisture and heat from reaching the
cold side 76.
The liquid tight compression fitting 139 may also increase the life of the
thermoelectric air
conditioner 7 by preventing moisture from reaching electrical components 159,
160, 161 and
162, thereby, increasing the life of the electrical components. As shown in
Figure 17, the
electrical components include a DC to DC active power supply 159, filter
capacitors 160, a
bridge rectifier 161, and a noise suppression filter 162, and associated
circuitry (not shown).
Sealant 138 may be disposed in wire feed opening 140 to further seal the wire
feed opening
140.
[0113] Figure 18 is an exploded perspective view of an exemplary
thermoelectric air
conditioner 7. As shown in Figure 18, thermoelectric air conditioner 7
includes at least one
thermoelectric module 141, at least one hot side heat sink 128, and at least
one cold side heat
sink 126. Mounting frame 72 includes at least one heat sink cutout 124. Heat
sink cutout 124
allows the thermoelectric modules 81 to contact both the hot side heat sink
128 and the cold
side heat sink 126. The contact between hot side heat sink 128 and cold side
heat sink 126
provides for heat transfer between the cold side 76 and the hot side 77
allowing the internal
cavity of the transit case to be cooled.
[0114] As shown, hot side heat sink 128 includes a base portion 142 and a
plurality of
fins 143 extending in a substantially orthogonal direction from the base
portion 142. The
plurality of fins 143 provides more surface area for better heat transfer.
[0115] Hot side heat sink 128 is preferably attached to the hot side 77 of
mounting
frame 72, proximate to heat sink cutout 124 through blind holes 144 and
fasteners 146. The
blind holes 144 provide for attachment to the mounting frame 72 without
providing a path for
air and moisture. This provides a moisture resistant barrier between the hot
side 77 and the
cold side 76, increasing thermal isolation and minimizing the risk of moisture
reaching the
thermoelectric modules 81 or electrical components 159, 160, 161 and 162 (not
shown). The
use of blind holes 144 also maximizes thermal isolation creating a moisture
resistant barrier
between the hot side 77 and the cold side 76.
[0116] In a preferred embodiment, a sealant is placed around the perimeter of
the
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base, between the hot side heat sink 128 and the mounting frame 72 to further
seal any gaps,
providing moisture resistance and thermal isolation. This moisture resistance
feature
functions to increase the long-term reliability of the thermoelectric air
conditioner 7.
[0117] Preferably, hot side heat sink 128 also includes a plurality of blind
holes 145
located along a centerline 147 of the base 82, opposite the plurality of fins
143. Blind holes
145 are provided to attach the cold side heat sink 126 to the thermoelectric
air conditioner 7
using fasteners 146. The blind holes 144 provide for attachment to the
mounting frame 72
without providing a path for air and moisture. This minimizes the risk of
moisture passing
between the hot side 77 and the cold side 76, increasing thermal isolation and
minimizing the
risk of moisture reaching the thermoelectric modules 141 or electrical
components 159, 160,
161 and 162 (not shown). The use of blind holes 144 also maximizes thermal
isolation by not
allowing air or moisture to flow between the hot side 77 and the cold side 76.
[0118] The thermoelectric air conditioner may also include a sealing frame 151
adapted to allow one or more thermoelectric modules 81 to be disposed therein
and to contact
the hot side heat sink 128 and the cold side heat sink 126. As shown, sealing
frame 151 is
attached to the cold side 76 of the mounting frame 72, proximate to heat sink
cutout 124,
with fasteners (not shown) secured into the blind holes 144 of the hot side
heat sink 128. The
sealing frame 151 provides the ability to seal against the mounting frame 72,
to secure
insulation 153 in place, and to seal between the sealing frame 151 and the
cold side heat
sinks 126. A sealant 138 is preferably placed between the sealing frame 151
and the
mounting frame 72 and between the sealing frame 151 and the cold side heat
sink 126.
[0119] Thermoelectric modules 81 have a relatively flat and planar body and,
as
shown in Figure 18, have a substantially rectangular shape. At least two wires
154 are
attached to the thermoelectric modules 81. Wires 154 provide a means for
applying power to
the thermoelectric modules 81. At least one thermoelectric modules 81 are
affixed to each
hot side heat sink 128, substantially coplanar with the mounting frame 72.
Preferably, the
thermoelectric modules 81 are substantially centered within each quadrant of
sealing frame
151.
[0120] Conductive material 155 is disposed on both the hot side 77 and the
cold side
76 of the thermoelectric modules 81 to promote good thermal coupling.
Preferably, the
conductive material 155 is a thermal grease.
[0121] In a preferred embodiment, one or more thermally conductive spacer
blocks
156 are placed on the cold side 76 of thermoelectric modules 81. Conductive
material 155 is
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disposed between the thermoelectric modules 81 and the thermally conductive
spacer blocks
156 to increase thermal conductivity. Thermally conductive spacer blocks 156
increase the
separation distance between the hot side heat sink 128 and the cold side heat
sink 126,
reducing thermal losses which may occur from any thermal short circuiting
between the hot
side heat sink 128 and the cold side heat sink 126.
101221 Cold side heat sink 126 includes a substantially rectangular base
portion 148
and a plurality of fins 149 extending in a substantially orthogonal direction
from the base
portion 148. The plurality of fins 149 provide more surface area for better
heat transfer.
[01231 As shown, cold side heat sink 126 is mounted with base portion 148
proximate
to on the thermally conductive spacer blocks 156 on the cold side 76 of
mounting frame 72
and with base portion 148 proximate the sealing frame 151. Cold side heat
sinks 126 contact
the thermally conductive spacer blocks 156. Preferably, conductive material
155 is applied
between the thermally conductive spacer blocks 156 and the cold side heat sink
126 to
promote thermal transfer. Preferably, cold side sink 126 also includes a
plurality of through
holes 150 corresponding to blind holes 145 in hot side heat sink 128. Through
holes 150 are
provided to attach the cold side heat sink 126 to the blind holes 145 of hot
side heat sink 128
using fasteners 146. Preferably, the fasteners 146 include sealing washers.
This minimizes
the risk of moisture = passing between the hot side 77 and the cold side 76,
increasing
thermal isolation and minimizing the risk of moisture reaching the
thermoelectric modules 81
or electrical components 159, 160, 161 and 162 (not shown).
[01241 As shown, insulation 153 ¨ having thermally insulating properties - is
disposed between the sealing frame 151 and the cold side heat sink 126 to
secure the
thermally conductive spacer blocks 156 and to provide increased thermal
isolation between
the hot side heat sink 128 and cold side heat sink 126. Thermoelectric module
wires 154 run
from the thermoelectric modules 81, are secured with wiring constraints 157
and run through
wire holes 152 located in sealing frame 151. Wire holes 152 are completely
sealed with
sealant 138 to increase thermal efficiency and to prevent moisture from
reaching the
thermoelectric modules 81.
[01251 The sealant 138 at various locations in the thermoelectric air
conditioner helps
form a moisture resistant barrier that resists the introduction of moisture
during operation of
the thermoelectric air conditioner 7. For example, humid moisture-laden air is
drawn through
the cold side heat sink 126. Once cooled, the air which may have humidity
levels
approaching 100% can no longer contain as much moisture as it cools, and the
air borne
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moisture then condenses onto the various cooling system components. Unless
moisture is
prevented from entering the thermoelectric air conditioner 7 by thoroughly
sealing the
thermoelectric modules 81 this moisture may ultimately saturate various
locations causing
damage to the thermoelectric modules 81 by, for example, chemical degradation,
electrolysis,
or the like. These sealing features also minimize moisture flow between the
hot side 77 and
the cold side 76, which improves thermoelectric air conditioner 7 efficiency.
101261 Additional details regarding the thermoelectric air conditioners can be
found
in U.S. Patent No. 6,345,507, entitled COMPACT THERMOELECTRIC COOLING
SYSTEM, issued on February 12, 2002 and U.S. Patent No. 6,499,306, COMPACT
THERMOELECTRIC COOLING SYSTEM, issued on December 31, 2002, the disclosures
of all of which are herein incorporated by reference.
101271 In addition, the thermoelectrically air conditioned transit case 1 may
include a
sealing system, such as a gasket 81, for sealing the connection between the
thermoelectric air
conditioner 7 and the transit case 2. Where the thermoelectric air conditioner
7 is mounted to
an opening 15 in the transit case 2, the gasket 81 can be disposed between the
mounting
flange 73 and the transit case 2 opening 15 and can be adapted to the size of
the opening 15
and mounting flange 73. Preferably, the gasket 81 is water and oil resistant
neoprene.
Fasteners 75, such as sealing screws (not shown), are disposed in through
holes 74 to secure
the mounting flange 73 to the transit case 2 opening 15. The use of a gasket
81 and sealing
screws 75 provide moisture resistance between the cold side 76 and the hot
side 77 (i.e.,
between the inside and the outside) when the thermoelectric air conditioner 7
is installed in
or on the transit case 2.
101281 The thermoelectric air conditioned transit case can also include
temperature
selection means and temperature sensing means for setting and monitoring a
temperature in
said internal cavity 14. For example, as shown in Figure 4 the temperature
selection means
can include a thermostat 105 for setting a desired temperature and the
temperature sensing
means can include a temperature probe 106 for monitoring the temperature in
the internal
cavity 14 of the transit case 2. The temperature can be varied by controlling
the current flow
through the thermoelectric device 7.
[01291 The thermoelectric air conditioner 7 includes a power source 159.
Preferably,
the power source can include AC and/or DC power. For example, the
thermoelectric air
conditioner 7 can include a power cord 121 for plugging into a standard power
receptacle. In
one preferred embodiment, the power source 159 includes a DC to DC active
power supply
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to minimize size and reduce waste heat. Preferably, the thermoelectric air
conditioner 7 is
designed with a programmable power control system to maximize cooling for a
given design
and operating conditions.
101301 In addition, the thermoelectrically air conditioned transit case 1 can
include a
case power source. In this embodiment, the thermoelectric air conditioner 7
can be
electrically connected (i.e., hard-wired or plugged into) to the case power
supply. The transit
case power supply can in turn include a plug and power cord that can be
connected to an
external power source (wall outlet, lighter adapter, aircraft adapter, etc.).
Furthermore, the
thermoelectrically air conditioned transit case 1 can include an
Uninterruptible Power Supply
(UPS).
101311 With overall weight of the portable thermoelectrically air conditioned
transit
case 1 being a concern, it is preferred that the transit cases 2 and the
thermoelectric air
conditioners 7 have light-weight designs. Preferably, the cases 2 include
light-weight designs
that use, for example, Thermo Stamped Composite (TSC), which is glass-
reinforced
polypropylene, Rotomolded PE (polyethylene), injection molded ABS, Fiberglass
(FRP),
and/or light-weight metal (such as Aluminum) materials. It is also
contemplated that other
light-weight composites and hybrid materials can be used. Other suitable
materials include
wood, fabric, canvas, vinyl, etc.
101321 Further, the weight of a thermoelectric air conditioner 7 can also be
reduced
by, for example, changing the materials of some of the components, such as
changing some
components to Aluminum, and also reducing the size of components. Also, the
thermoelectric air conditioner 7 can include a compact design, a light-weight
power supply
design and lay-out to help keep the weight of the overall thermoelectrically
air conditioned
transit case 1 to a minimum.
101331 Several exemplary embodiments are outlined below illustrating systems
and
methods for cooling the contents of a transit case and for mounting a
thermoelectric air
conditioner 7 to a transit case 2.
101341 Figures 1-4 show an exemplary internal thermoelectric air, conditioner
7
embodiment. As shown, the case has front and rear covers 20 (although cases
having a single
cover are also contemplated) and a metal frame 40 inside the case internal
cavity 14. As
shown, the frame includes a 19-inch rack-mount frame 40. The covers 20 can
also be called
lids, doors, etc., and can be hinged or entirely removable. The thermoelectric
air conditioner
7 mounts on the end of the frame 40, concealed inside the case when in the
transit mode,
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viewable when in the operational mode. As shown, shock mounts 93 are
positioned between
the frame 40 and the walls 10 of the case 2. As shown, the thermoelectric air
conditioner 7 is
installed through the end opening 15 of the case 2. The cold side 76 of the
thermoelectric air
conditioner 7 extends into an opening 42 in the frame 40 and the mounting
flange 73 of the
thermoelectric air conditioner 7 is connected to the frame 40. A tongue 84 and
groove 85
arrangement is shown for sealing the opening 15 when the cover 20 is secured
over the end
opening 15 of the case 2. An adapter plate 82 is also shown for filling-in and
sealing the
space between the thermoelectric air conditioner 7 and the case walls 10. In
this embodiment,
the air conditioner 7 is totally contained within the case 2 when the cover 20
is secured to the
case 2 over the end opening 15. In this configuration, not only can one not
tell there is an air
conditioner 7 incorporated into the case 2 when the case 2 is in the transit
mode, but the air
conditioner 7 is totally protected by the design of the case 2, the mounting
arrangement, the
shock-mounted frame 40, etc.
[0135] Figures 5 and 6 show another internal thermoelectric air conditioner 7
embodiment. In the illustrated embodiments, the case includes a top cover 20
and the
thermoelectric air conditioner 7 mounts inside the case 2 on a mounting plate
30 that is
secured to the opening 15 of the case 2. As shown, the thermoelectric air
conditioner 7 is
concealed when in the transit mode and viewable when in the operational mode.
In this
embodiment, the top cover 20 is pivotally connected to the case 2 by hinges 27
and the
thermoelectric air conditioner 7 is totally contained within the case 2 when
the top cover 20
is closed. When the case 2 is in the transit mode, it is not apparent there is
a thermoelectric
air conditioner 7 incorporated into the case 2, and the air conditioner 7 is
totally protected by
the design of the case 2, the mounting arrangement, the shock-mounted frame
40, etc. As
shown in Figure 5, the case 2 can include wheels 100 to assist in the
portability of the transit
case 2.
[0136] Figures 7A-B show cases 2 with a top cover 20 and Figure 8 shows a case
2
with an end cover 20. In each figure, the thermoelectric air conditioner 7
mounts on the top
or side or end of the case 2. In the embodiments of Figures 7A, 7B, and 8, the
thermoelectric
air conditioner 7 is not concealed inside the case 2 when the case 2 is in the
transit or
operational mode. Figure 7A shows a horizontal, through-mounted thermoelectric
air
conditioner 7 on top of the case 2, wherein at least a portion of the cold
side 76 of the
thermoelectric air conditioner 7 extends into the internal cavity 14 of the
case 2. Figure 7B
shows a horizontal, flush-mounted thermoelectric air conditioner 7 on top of
the case 2,
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wherein no portion of the thermoelectric air conditioner 7 extends into the
internal cavity 14
of the case 2. Although not shown, the embodiments of Figures 7A and 7B can
include a
separate transit lid 25 for covering and protecting the thermoelectric air
conditioner 7 during
transit. The transit lid 25 can include a plastic, metal, and/or wire mesh
configuration.
[01371 Figure 8 shows a case having front and rear covers 20 where the
thermoelectric air conditioner 7 mounts on the top of the case 2. Figure 8
shows a horizontal,
through-mounted thermoelectric air conditioner 7 on one side of the case 2,
wherein at least a
portion of the thermoelectric air conditioner 7 extends into the internal
cavity 14 of the case
2. The thermoelectric air conditioner 7 is not concealed inside when the case
2 is in the
transit or operational mode. Similar to the embodiments of Figures 7A-7B, the
thermoelectric
air conditioner 7 of Figure 8 may be flush-mounted and/or through-mounted.
Although not
shown, the embodiment of Figure 8 can include a separate transit lid 25 for
covering and
protecting the thermoelectric air conditioner 7 during transit. Also, the
thermoelectric air
conditioner in any of the flush-mounted and/or through-mounted embodiments
could be
mounted vertically at one side or end of the case 2.
101381 The thermoelectric air conditioner 7 may also be removably mounted in
or on
the transit case 2 although this is more preferred for embodiments wherein the
thermoelectric
air conditioner 7 is externally mounted. In the embodiments of Figures 9A and
9B, the
thermoelectric air conditioner 7 is removably mounted to the mounting plate 30
of the transit
case 2. As shown in Figure 9A, the thermoelectric air conditioner 7 is not
concealed inside
the case 2 when the case 2 is in the operational mode. But during transit the
thermoelectric
air conditioner 7 can be removed and can be stowed within the transit case 2
and thus can be
concealed inside the case 2 when the case 2 is in the transit mode, as shown
in Figure 9B.
[0139] Alternatively, as shown in Figures 10A-10D the thermoelectric air
conditioner
cam be shipped and protected in a separate case 2b. Once on-site the
thermoelectric air
conditioner can be removed from its shipping case 2b (secondary case 2b) and
connected to
the transit case 2a housing the temperature sensitive equipment 5 (primary
case 2a) and
placed in operation.
[0140] Figure 11 shows an alternate embodiment of the externally mounted
thermoelectric air conditioner 7 further comprising a separate, secondary
cover 25 for
containing and protecting the thermoelectric air conditioner during transit.
Once on-site, this
secondary cover 25 can be removed exposing the thermoelectric air conditioner
7 for
operation. This embodiment shows a case having a top cover 20 and the
thermoelectric air
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conditioner 7 mounted on the top of the case 2, but is also applicable for
cases 2 having an
end cover 20 and the thermoelectric air conditioner 7 mounted on the end of
the case 2. In
this embodiment, the thermoelectric air conditioner 7 is concealed inside the
secondary cover
25 when the case 2 is in the transit mode.
[0141] Figures 12A-12B and 13A-13B illustrate yet other embodiments wherein
the
thermoelectric air conditioner 7 is mounted in an extender piece 37 (Figures
12A-12B)
and/or a secondary case 2b that is separate from the primary case 2a housing
the equipment 5
to be protected (Figures 13A-13B). Preferably, the extender piece 37 and/or
secondary case
2b include removable covers/lids/panels 25 on corresponding mating wall (e.g.,
top/bottom,
end/end, side/side) as the mating wall of the primary case 2a, which is
includes a removable
cover 20a.
[0142] This allows, for example in the case of an embodiment having a
secondary
case,
the two cases 2a,2b to be connected such that the thermoelectric air
conditioner 7 in the
secondary case 2b is in thermal communication with the internal cavity 14a of
the primary
case 2a in order to control the temperature of the internal cavity 14a of the
primary case 2a.
The removable cover/lid/panel 20b on the secondary case 2b (i.e., the case
housing the
thermoelectric air conditioner 7) covers and protects the thermoelectric air
conditioner 7
during transit. The removable cover/lid/panel 25 on the primary case 2a (i.e.,
the case
housing the equipment 5) covers and protects the equipment 5 during transit.
[0143] During operation, the two removable covers/lids/panels 25 are removed
and
the primary and secondary cases 2a, 2b are connected to one another. The
openings 15a, 15b
in the cases 2a, 2b wherein the covers/lids/panels 25 were removed allows the
thermoelectric
air conditioner 7 to be in thermal communication with the internal cavity 14a
of the primary
case 2a. Alternatively, as shown in Figures 13A and I 3B air passageways can
be formed
between the cold side 76 of the thermoelectric air conditioner 7 in the
secondary case 2b and
the internal cavity 14a of the primary case 2a to help facilitate air flow
between the
thermoelectric air conditioner 7 and the internal cavity 14a. Also, the
primary 2a and
secondary 2b cases can be connected end-to-end, as shown in Figures 12A and
12B, and/or
one on top of another, as shown in Figures 13A and 13B.
[0144] In still another embodiment, a standard "vertical" mounting orientation
of an
exemplary thermoelectric air conditioner 7 provides for the long side of the
mounting flange
73 on the thermoelectric air conditioner 7 to be in the vertical direction. In
this type of
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arrangement, the thermoelectric air conditioner 7 can be rotated approximately
90 degrees so
that it would match with the dimensional constraints of the transit case 2.
101451 This arrangement requires features that deal with condensate collection
issues.
Condensate collection can be addressed through the use of one or more of the
following
features: (1) slotted heat sink fins 107 which allow condensate to be drawn
down by gravity
(see Figure 19); (2) a modified "cold side" cover 110 which includes a built-
in and/or
separate condensate drip pan 108 at the bottom (see Figures 20a and 20b,
respectively); (3)
desiccant containers (not shown) that can be mounted within the transit case 2
to aid in
absorbing moisture. The desiccant can include a feature to indicate when it is
expired or used
up. For example, the desiccant can change color when it requires
renewal/replenishment. As
shown in Figure 20b, the condensate drip pan 108 can also include a hose 109
for leading any
condensation away from the thermoelectric air conditioner 7.
[01461 Figures 21A-21F shows several views of one exemplary thermoelectrically
air
conditioned transit case 1. Figure 21A shows a transit case 2 with front and
rear covers 20 in
place. As shown, two (of four) handles 91 are visible. The front and rear
covers 20 are
secured to the case 2 housing by latches 96.
101471 Figure 21B is a front view showing the front cover 20 partially
removed. Rack
rails 45, such as 19-inch rack rails, can be used for mounting both the
equipment 5 as well as
the thermoelectric air conditioner 7. For example, a 19-inch oscilloscope is
shown in Figure
21B. Shock mounts 93 are disposed between the case walls 10 and the rack rails
45. Other
equipment and/or an adapter plate (not shown) may be connected to the rack
rails below the
depicted oscilloscope to fill the front opening and seal the interior space.
[0148] Figure 21C shows the front cover 20 removed entirely. As shown,
complete
access to the front side of the equipment 5 is provided. As shown, a rack
frame 40 has a 24-
inch depth (rail to rail). Other frame sizes are also available having varying
dimensions, such
as, for example, between about 17 to about 30-inch depth. In this embodiment,
the front
cover 20 is on when the transit case 2 is being transported and can be removed
and/or left in
place when the thermoelectric air conditioner 7 is cooling the electronics
within the case 2.
An adapter plate (not shown) can be mounted below and around the equipment 5
to seal the
internal cavity 14 during operation when the cover 20 is removed.
[0149] Figure 21D is a rear view showing both covers 20 (rear and front) in
place. As
shown, the thermoelectric air conditioner 7 is completely concealed and
contained within the
case 2.
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[0150] Figure 21E shows the rear cover 20 partially removed. Preferably, the
rear
cover 20 is on when the transit case is being transported and off when the
thermoelectric air
conditioner 7 is cooling the electronics within the case 2. The thermoelectric
air conditioner 7
and adapter plate 82 seal the interior cavity 14 from the outside environment.
[0151] Figure 21F shows the rear cover 20 removed entirely. Rack rails 45,
such as
the same I9-inch rack rails used to hold the equipment 5, can be used to mount
the
thermoelectric air conditioner 7 in a special orientation, with special light-
weight (e.g.,
Aluminum) components, a special (AC and/or DC) power arrangement, and a
special light-
weight adapter plate82/gasket 81 assembly to seal out contaminants. Power
cables 121 can
exit through a connector (not shown) positioned on the adapter plate 82.
101521 While systems and methods have been described and illustrated with
reference
to specific embodiments, those skilled in the art will recognize that
modification and
variations may be made without departing from the principles described above
and set forth
in the following claims. Accordingly, reference should be made to the
following claims as
describing the scope of disclosed embodiments.
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