Note: Descriptions are shown in the official language in which they were submitted.
CA 02865781 2017-02-14
REMOVABLE ACCESS PANELS AND TRANSITIONS IN HVAC
SYSTEMS
FIELD OF DISCLOSURE
[00011 This disclosure generally relates to a transition for air
conditioning systems having
box evaporator coils or slab type evaporator coils ("coils"). More
particularly, this disclosure
relates to systems, methods and devices that involve a transition having one
or more
removable door panels, which permits in situ access to evaporator coils.
BACKGROUND
[0002] To maintain, improve, or fix the working condition of an air
conditioning system,
cleaning, repairing, or replacing its components may be necessary. Adequate
access to these
components, however, may prove difficult. For instance, with systems having
evaporator
coils ("coils"), reaching these malfunctioning, inefficient, or inoperable
components often
requires at least partial disassembly. After the particular problem with the
coils is remedied,
then the air conditioning system must be re-assembled and sealed. Accordingly,
these
subordinate processes wind up consuming the vast majority of time necessary to
resolve the
coil issue or an issue or maintenance issue with the forced air-handling unit
("AHU")
adjoined to it. As a result, the time required to remedy the coil or AHU issue
makes attendant
costs so undesirable that a cost-efficient solution from a big-picture
perspective may become
replacing the used coils with a new coils or replace the AHU rather than
merely remedying
the particular problem with the used coils or AHU. Consequently, used coils or
AHU's are
replaced and new coils or AHU's are installed prematurely, a situation
squandering time,
money and materials.
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SUMMARY OF THE INVENTION
[0003] In
one embodiment, the system includes air conditioning system. The system may
include a furnace having a motor and a blower or other type of forced air-
handling unit
(AHU). Further, the system may include a transition having at least one
removable access
panel, wherein the transition has a first opened end and a second opened end
located opposite
of the first opened end, further wherein the first opened end securably aligns
with an opened
end of the AHU, and further wherein the evaporator coils are accessible via
the at least one
removable access
panel. Further still, the system may include a housing unit housing
evaporator coils, wherein the second opened end securably aligns with one
opened end of the
box, further wherein the evaporator coils and the heat exchanging components
of the AHU are
accessible via the removable access panel.
[0004] In
another embodiment, a method includes accessing an interior of an air
conditioning system, such as its evaporator coils or the heat exchanging
components of the
AHU. The method may include unfastening one or more fastening devices that
removably
engage a removable access door from a frame, wherein the removable access door
and the
frame are the primary components of a removable access panel of a transition
with the air
conditioning system. Further, the method may include removing the removable
access door
from the frame. Further still, the method may include extending an object
comprising an
appendage, object or tool into the interior of the air conditioning system.
[0005] In
yet another embodiment, a method includes making a transition, such as for use
in accessing evaporator coils or the heat exchanging components of the AHU of
an air
conditioning system. The method may include adjoining a series of at least
three members
forming a perimeter of the transition, wherein the series comprises an end of
a wall or a
removable access panel frame adjoined to another end of another wall or
removable access
panel frame. Further, the method may include providing a removable access door
that
removably connects with the removable access panel frame via one or more
fastening devices.
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,
,
[0006] In still yet another embodiment, a device is a transition,
which may be used for
accessing an interior of an air condition system, such as its evaporator coils
or the heat
exchanging components of the AHU. The device may include a series of at least
three
insulated members that form a perimeter of the transition, wherein the series
comprises an end
of a wall or a removable access panel frame adjoined to another end of another
wall or
removable access panel frame. Further, the device may include a removable
access door that
removably connects with the removable access panel frame via one or more
fastening devices.
Further still, the device may include one or more pre-punched holes on one or
more of the at
least three members.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] So that the manner in which the above recited features,
advantages and objects of
the present invention are attained and can be understood in detail, a more
particular
description of the invention, briefly summarized above, may be had by
reference to the
embodiments thereof which are illustrated in the appended drawings.
[0008] It is to be noted, however, that the appended drawings
illustrate only typical
embodiments of this disclosure and are therefore not to be considered limiting
of its scope, for
the disclosure may admit to other equally effective embodiments.
[0009] FIG. 1 depicts prior art of a side view of a system containing
coils.
[0010] FIG. 2 depicts an example embodiment of a side view of a
system in accordance
with the disclosed methods and systems.
[0011] FIG. 3a depicts an example embodiment of a perspective view of
a transition
within a system in accordance with the disclosed methods and systems.
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[0012] FIG. 3b depicts an example embodiment of a side view of a double-
walled version
having insulation therebetween, wherein the double-walled version may be used
for any side,
such as a wall or removable access panel, within a transition, and,
furthermore, in accordance
with the disclosed methods and systems.
[0013] FIG. 4 depicts an example embodiment of a vertical arrangement of a
system
having a transition and a drain pan in accordance with the disclosed methods
and systems.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0014] The following is a detailed description of example embodiments of
the invention
depicted in the accompanying drawings. The embodiments are examples and are in
such
detail as to clearly communicate the invention. However, the amount of detail
offered is not
intended to limit the anticipated variations of embodiments; on the contrary,
the intention is to
cover all modifications, equivalents, and alternatives falling within the
spirit and scope of the
present invention as defined by the appended claims. The detailed descriptions
below are
designed to make such embodiments obvious to a person of ordinary skill in the
art.
[0015] In addition, directional terms, such as "above," "below," "upper,"
"lower," "front,"
"back," "top," "bottom," etc., are used for convenience in referring to the
accompanying
drawings. In general, "above," "upper," "upward," "top," and similar terms
refer to a
direction away the earth's surface, and "below," "lower," "downward,"
"bottom," and similar
terms refer to a direction toward the earth's surface, but is meant for
illustrative purposes
only, and the terms are not meant to limit the disclosure.
[0016] Generally disclosed are methods and systems with regard to
manufacturing and
accessing evaporator coils ("coils") for transitioning within an air
conditioning system having
these coils. The coils, themselves, may be any type of coils, and, for
instance, include box
coils or slab coils, either of which may be in an arrangement that is
horizontal, vertical, or a
combination thereof. Example box coils include multi-poise A-coil, performance
A-coil, and
N-coil.
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[0017] Turning now to FIG. 1, this figure depicts an example embodiment of
a side view
of the prior art. Here, the system 100 includes a forced air-handling unit
("AHU") 110 having
a motor 112 and a blower 115 connected to a housing 130 having box evaporator
coils or slab
type evaporator coils ("coils") 133 therein 130. A plenum 140 connects to the
housing 130 at
a different place than where the AHU 110 connects to the housing 130; that is,
at a place other
than the one opened end 231 as depicted in FIG. 3. Returning to FIG. 1, the
connection
between the AHU 110 and the housing 130 permits the airflow 150 there through,
but this
airflow 150 is noticeably restricted by the block-off 120 connected to the
housing 130. The
block-off 120 accommodates for the mismatch between the opened-end interface
of the AHU
110 connecting to the open-ended interface of the housing 130. That is,
without the block-off
120, the system 100 would not be a closed system 100 because the airflow 150
would be
disrupted on account of the housing 130 having an open-ended portion (i.e.,
equal to the
surface area of the block-off 120) exposed to the surroundings of the system
100.
[0018] To circumvent problems in the prior art, such as those systems and
problems
discussed above, as well as provide further solutions to the industry,
disclosed are methods
and systems accompanied by the figures. As shown in Figure 2, the system 200
is a closed
system and includes a transition 210 that conjoins and flanks two components
220, 230,
namely an AHU 220 and the housing unit 230 having the coils. The AHU, 220, for
example,
may include but is not limited to including a blower and a furnace, wherein
each may be
powered by gas, electric, solar or otherwise; the AHU 220 may include other
components as well. The
transition 210 may comprise any suitable shape to conjoint these components
220, 230. An example
suitable shape for the transition 210, 310 is quadrilateral, such as that
shown in Figure 3. An example
of a quadrilateral shape is trapezoidal.
[0019] Figure 3a illustrates a perspective view of part of a system, such
as systems 200 and/or
400, having a transition 310 with a quadrilateral shape. In an example
embodiment, the transition 310
may have three walls 311, 312, 313, a removable access door 314 and frame 321
(collectively referred
to hereafter as "removable access panel") an open top 315, and an open bottom
316. The three walls
311, 312, 313 and removable access panel 314, 321, when the removable
CA 02865781 2014-10-02
access door 314 is in an un-removed state (i.e., just the opposite of the
depiction in Figure 3a),
may form a continuous, enclosed perimeter for the transition 310 in any one or
combination
of multiple ways. For instance, one of the three walls 311, 312, 313 or
removable access
panel's frame 321 may be welded at the end of one of the three walls 311, 312,
313 or
removable access panel's frame 321 to adjoin, at a right angle in this case
but the angle may
be different in another example embodiment, with respect to the end of another
one of the
three walls 311, 312, 313 or removable access panel's frame 321, and so forth,
in order to
form a continuous, enclosed perimeter for the transition 310. In
another example
embodiment, one of the three walls 311, 312, 313 or removable access panel's
frame 321 may
be adjoined in another way to the end of another one of the three walls 311,
312, 313 or
removable access panel's frame 321 at a right angle by another way, e.g.,
riveting, screwing,
other fastening devices, or combinations thereof. In yet another example
embodiment, one of
the three walls 311, 312, 313 or removable access panel's frame 321 may be
adjoined to the
end of another one of the four walls 311, 312, 313 or removable access panel's
frame 321 at a
right angle by extruding at least part of the transition 310. And, in yet
another example
embodiment, at least two of the three walls 311, 312, 313 or removable access
panel's frame
321 are integrally connected, wherein a right angle between the at least two
of the three walls
311, 312, 313 or removable access panel's frame 321 is formed by molding,
bending, folding,
or otherwise manipulating material(s) comprising the at least two of the three
walls 311, 312,
313 or removable access panel's frame 321 of the transition 310. To that end,
the transition
310, itself, and any of its 310 components, may be made of one or more
materials that include
metal, plastic, wood, other suitable materials, or combinations thereof Each
edge 320,
whether formed by adjoining, integrally connecting, or otherwise as previously
disclosed or
known, of the three walls 311, 312, 313 or removable access panel's frame 321
may be
smooth, a desirable quality for safety and/or aesthetics.
[0020] One
or more of the three walls 311, 312, 313 or removable access panel 314 may
be proximate to insulation. In example embodiments, the insulation may be
attached to any
part(s) of the three walls 311, 312, 313 or removable access panel 314, 321,
preferably within
the interior 325 as opposed to the exterior 330, by adhesive, insulation pins,
or other fastening
devices. In another example embodiment, the insulation is not attached, but
merely abuts
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part(s) of one or more of the three walls 311, 312, 313 or removable access
panel's frame 321.
In yet another example embodiment, the insulation, whether attached or not
attached, is
located between a double-walled version 340 of one or more of the three walls
311, 312, 313
or removable access door 314. That is, wall 311, for example, may be a double-
walled
version 340 that includes insulation 335 flanked by two walls 341, 342 as
shown in Figure 3b.
A frame 350 may encapsulate the insulation 335 within each double-walled
version 340, and,
thereby, provide additional integrity to the transition 310. In such a case,
one or more of the
three walls 311, 312, 313 or removable access panel's frame 321 may still be
adjoined at right
angles in any of the manners previously described or known. Similarly, walls
341, 342 may
have lips, folded edges, complimentary mating mechanisms, or otherwise to
permit adjoining
wall 341 to wall 342 (i.e., pictorially demonstrated as adjoined edge of the
walls 341, 342) in
any of the manners previously described or known. In other example
embodiments, the
double-walled version 340 has no internal frame 350. In line with energy-
efficiency
considerations, the system may contain insulated walls that are at least
equal, i.e., meets or
exceeds, the thermal resistance value ("R-value") of the system.
[0021] While additionally addressing size as well as shape, the transition
210, 310, itself,
may be customized to a customer's size and shape requirements for his
particular system 200,
300. In other embodiments, the transition 210, 310 may be manufactured in a
range of
industry-accepted sizes and shapes. In additional example embodiments, the
transition 210,
310 may be manufactured in accordance with local building and/or energy code
requirements.
In still yet additional embodiments, the transition 210, 310 may be
manufactured in a specific
or range of R-values and/or meet governmental or industry requirements,
accreditations,
certifications, etc. Thus, in varying embodiments, the transition 210, 310 may
be customized,
readily available for off-the-shelf installation, or an embodiment
therebetween.
[0022] When used in a system 400, such as one 400 having a vertical
arrangement 405 of,
for example, the AHU 420 and the housing unit 430 having the coils, but not to
the exclusion
of a horizontal or other arrangement, the transition 410 may work in tandem
with a drain pan
440 within a closed system. The drain pan 440 may allow for collection of
liquids resulting
from drainage during maintenance, cleaning, installation, condensation, or
other reason.
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[0023] Returning to the discussion of the example embodiment having three
walls 311,
312, 313 or removable access panel 314, 321 any one or more of these three
walls 311, 312,
313 or removable access panel 314, 321 in this embodiment or others, may have
one or more
pre-punched holes 355 of any kind. The pre-punched holes 355 may permit a
removable cap
access that creates an opening when punched for a variety of reasons, e.g.,
installing and/or
mounting of: ultraviolet radiant tube devices on the interior, exterior, or
combinations thereof
of any of the one or more of these three walls 311, 312, 313 or removable
access panel 314,
321 having one or more pre-punched holes 355; air flow and air quality
metering devices;
heating, ventilation, and air conditioning ("HVAC") temperature, pressure and
other types of
probes or metering devices for testing temperature, pressure, and other
metrics within the
system 300, such as the coils. The mounting may be accomplished, for example,
by any
fastening devices and methods previously disclosed or otherwise known or
available.
[0024] Now turning to the removable access panel 314, 321 shown in Fig. 3,
a more
detailed discussion ensues as to its 314, 321 disclosure and its 314, 321
various embodiments.
The removable access panel 314, 321 provides access to the interior 325 of the
transition 310
for cleaning, repairing, maintaining, or replacing of components, or for any
other reason, by
removing the removable access door 314 of a system, such as systems 100, 200,
400. The
frame 321 is optionally recessed within the transition 310 and/or structurally
reinforced to
provide further integrity to the transition 310; structural reinforcement may
be more of a
concern in a vertical arrangement 405, as in system 400, as opposed to a
horizontal
arrangement, as in system 200. Reinforcement materials may include metal,
plastic, wood,
other suitable materials, or combinations thereof. In alternate, example
embodiments, one of
more of the three walls 311, 312, 313 may comprise removable access panel,
such as
removable access panel 314, 321 such that the transition 310 has more than one
side having a
removable access panel.
[0025] The removable access door 314 may be secured within the frame 321 of
the
removable access panel 314, 321 through one or more fastening device(s) 323.
The fastening
device(s) 323 may include swivel latch(es), spring clamp latch(es), spring
pressure latch(es),
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hook(s) and loop(s), locks, and/or other devices that are located and operable
on: (1) any part
of the removable access door's 314 exterior 330, interior 325, in between the
exterior 330 and
interior 325, or combinations thereof; and (2) any part of the frame's 321
exterior 330, interior
325, in between the exterior 330 and interior 325, or combinations thereof.
Through such
fastening device(s) 323, the removable access doors 314 and the frame 321
collectively
provide a removable access panel 314, 321, wherein a closed, removable access
door 314
results in a closed system and an opened, removable access door 314 results in
an opened
system, such as the one depicted in Figure 3. In further example embodiments,
the interior
perimeter of the frame 321 and/or the perimeter of the removable access door
314 may
include a sealing material, such as rubber, to enhance the seal formed between
the frame 321
and the removable access door 314 when the removable access panel 314, 321 is
in a closed
state. A system may include a sealing material in order to minimize leaks from
and to a
system that includes one or more removable access panels such as removable
access panel
314, 321.
[0026] Turning to another aspect, disclosed are methods of accessing an
interior of an air
conditioning system. A method may include unfastening one or more fastening
devices 323
that removably engage a removable access door 314 from a frame 320, wherein
the removable
access door 314 and the frame 320 are primary components of a removable access
panel 314,
321 of a transition 310 for the air conditioning system. Further, the method
may include
removing the removable access door 314 from the frame 321. Further still, the
method may
include extending an object, such as an appendage, tool, or other object, into
the interior of
the air conditioning system. Here, the interior of the air conditioning system
may be in the
AHU and/or the housing unit housing the coils in order to clean, remove,
replace, maintain or
otherwise act on the air conditioning system and its components.
[0027] In yet another aspect, disclosed are methods of making a transition
314. The
method may include adjoining a series of at least three members (314 and at
least two of 311,
312, or 313, for example) and forming a perimeter of the transition 310,
wherein the series
(314 and at least two of 311, 312, or 313, for example) comprises an end of a
wall (at least
two of 311, 312, or 313, for example) or a removable access panel frame 321
adjoined to
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another end of another wall (at least two of 311, 312, or 313, for example) or
removable
access panel frame 321. The method may also include providing a removable
access door
314 that removably connects with the removable access panel frame 321 via one
or more
fastening devices 323. During or after making the transition, the at least
three members (314
and at least two of 311, 312, or 313, for example) may be insulated.
[0028] In still yet another embodiment, disclosed is a device having a
series of at least
three insulated members (314 and at least two of 311, 312, or 313, for
example) that form a
perimeter of the transition 310, wherein the series comprises an end of a wall
(at least two of
311, 312, or 313, for example) or a removable access panel frame 321) adjoined
to another
end of another wall (at least two of 311, 312, or 313, for example) or
removable access panel
frame 321. The device may include a removable access door 314 that removably
connects
with the removable access panel frame 321 via one or more fastening devices
323.
Additionally and alternatively, the device may include one or more pre-punched
holes 355 on
one or more of the at least three members (314 and at least two of 311, 312,
or 313, for
example).
[0029] While the foregoing is directed to example embodiments of the
disclosed
invention, other and further embodiments of the invention may be devised
without departing
from the basic scope thereof, and the scope thereof is determined by the
claims that follow.
