Support bracket for casing of a condensing unit
A support bracket suitable for use in a casing of an outdoor condensing unit includes a main body configured to reside between a corner post and a coil of the condensing unit, a first extension member extending from a first end of the main body, and a second extension member extending from a second end of the main body. The first extension member is configured to attach to a first inlet grille of the condensing unit. The second extension member is configured to attach to a second inlet grille of the condensing unit.
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The present invention relates generally to a support. More particularly, the present invention relates to a support bracket configured to support a protective casing for a condenser coil.
A split system heating and/or cooling system includes an outdoor unit, such as a condensing unit, and an indoor unit, such as an evaporator unit. The condensing unit typically includes a condenser coil, inlet grilles for protecting the coil, a top cover, and a base pan for containing the condensing unit and receiving condensation that drips from the coil.
Commonly, the condensing unit includes an inlet grille on each of the four sides of the condensing unit. A corner post may be used at the corners of the condensing unit to secure each end of the inlet grilles.
BRIEF SUMMARY OF THE INVENTIONThe present invention relates to a support bracket suitable for use in a casing of an outdoor condensing unit. The support bracket includes a main body configured to reside between a corner post and a coil of the condensing unit, a first extension member extending from a first end of the main body, and a second extension member extending from a second end of the main body. The first extension member is configured to attach to a first inlet grille of the condensing unit. The second extension member is configured to attach to a second inlet grille of the condensing unit.
First inlet grille 18 and second inlet grille 20 are configured for protecting coil assembly 14, which includes copper tubing and thin aluminum fins that are used to form a coil. Condensing unit 10 includes two additional inlet grilles, which are not visible in
First corner post 24 resides between first and second inlet grilles 18 and 20, and also protects coil assembly 14. Corner post 24 may be attached to top cover 16 and to base pan 14. First and second inlet grilles 18 and 20 may also be attached to top cover 16 and to base pan 14. A portion of second corner post 28 is also visible in
Although the discussion below is in reference to first inlet grille 18, second inlet grille 20, and first corner post 24, this discussion also applies to the other inlet grilles and corner posts of condensing unit 10.
During manufacturing and assembly of condensing unit 10, top cover 16 may be attached to unit 10. Top cover 16 may be assembled onto unit 10 during the final or near final steps of the manufacturing and assembly process. Top cover 16 may serve as a support for inlet grilles 18 and 20 near a top portion of coil assembly 14. Thus, inlet grilles 18 and 20 may not be supported near a top portion of coil assembly 14 until top cover 16 is attached to unit 10. As a result of this lack of support, inlet grilles 18 and 20 may bow away from coil assembly 14 during assembly of condensing unit 10. If inlet grilles 18 and 20 bend beyond a certain point, the structural integrity of the grilles may be comprised, which may lead to failure or breakage.
In order to attach top cover 16 to corner post 24, an aperture in a center of a top portion of corner post 24 may be used to receive a fastener that first passes through top cover 16. If only one fastener is used to fix top cover 16 to corner post 24, corner post 24 may not be adequately secured to top cover 16, in terms of preventing movement of corner post 24. As such, the sides of corner post 24 may be able to bend around a center of corner post 24 and rattle against top cover 16.
Inlet grilles 18 and 20 and corner post 24 are configured as a cage or casing around coil assembly 14 to protect the coil. However, in designs as described above, in which a fastener is used to fix top cover 16 to corner post 24, an end of the fastener may likely puncture the coil during shipping or assembly.
The present invention relates to a support bracket suitable for use in outdoor condensing unit 10 in order to provide support to inlet grilles 18 and 20 and corner post 24, as well as protect coil assembly 14. The support bracket is configured to eliminate the potential for the problems mentioned above.
As described in more detail below, support bracket 30 is configured to be located between corner post 24 and coil assembly 14 of
Main body portion 32 of support bracket 30 is configured to be located behind corner post 24. Main body portion 32 includes rib 44, which provides rigidity to main body portion 32.
First tab member 34a and second tab member 34b are each configured to engage with corner post 24, as described in further detail below with reference to
As shown in
First extension member 36a includes first corner portion 38a, which has long portion 48a extending from an end of tab member 34a and short portion 50a that connects with fastener portion 40a. Long portion 48a and short portion 50a are oriented approximately 90 degrees relative to one another such that a flange on corner post 24 is configured to rest against short portion 50a. Similarly, second extension member 36b includes second corner portion 38b having long portion 48b extending from an end of second tab member 34b and short portion 50b connecting to second fastener portion 40b. A second flange located on an opposite side of corner post 24 is configured to rest against short portion 50b of second corner portion 38b. As shown in
Support bracket 30 is configured such that main body portion 32 is rigid, while first and second extension members 36a and 36b are flexible. Support bracket 30 may be formed from any metal or any other suitable material. In a preferred embodiment, support bracket 30 may formed from a sheet metal made of steel. Support bracket 30 may be formed by various known stamping techniques, including, but not limited to, using a progressive die.
Corner post 24 includes aperture 60, which is located in a center of corner post 24 and is configured for receiving a fastener that attaches top cover 16 (not shown) to corner post 24. Because main body portion 32 of support bracket 30 is located behind corner post 24, support bracket 30 protects coil assembly 14 from being punctured by the fastener received through corner post 24.
As shown in
As shown in
Support bracket 30 provides further support to corner post 24 by way of first corner portion 38a and second corner portion 38b. As explained above in reference to
To assemble a condensing unit similar to condensing unit 10 of
These steps, attaching a grill, then a corner post, then a second grill, are repeated until condensing unit 10 includes four inlet grilles, three corner posts, and a control box. In reality, assembly of unit 10 may likely begin with one of the inlet grilles that are not visible in
Finally, top cover 16 is placed on unit 10 and fasteners are used to secure top cover 16 at various positions around unit 10. As explained above, a fastener is received through top cover 16 and aperture 60 of corner post 24 to attach top cover 16 and corner post 24. In addition, a second fastener is received through top cover 16, aperture 46a of support bracket 30, and aperture 64 of first inlet grille 18. A third fastener is received through top cover 16, aperture 46b of support bracket 30, and aperture 68 of second inlet grille 20.
It is recognized that various methods may be used to assemble condensing unit 10, in addition to or as an alternative to the steps outlined above.
The terminology used herein is for the purpose of description, not limitation. Specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as bases for teaching one skilled in the art to variously employ the present invention. Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
Claims
1. A support bracket suitable for use in a casing of an outdoor condensing unit, the support bracket comprising:
- a main body configured to reside between a corner post and a coil of the condensing unit;
- a first extension member extending from a first end of the main body; and
- a second extension member extending from a second end of the main body, wherein the first extension member is configured to engage with a first inlet grille of the condensing unit and the second extension member is configured to engage with a second inlet grille of the condensing unit.
2. The support bracket of claim 1, wherein the main body comprises a first tab member and a second tab member that are each configured to engage with the corner post.
3. The support bracket of claim 2, wherein the first and the second tab members each include a dimple configured to align with a first hole and a second hole of the corner post.
4. The support bracket of claim 1, wherein the first extension member includes an aperture for receiving a fastener through the first extension member to attach the first extension member to a post of the first inlet grille.
5. The support bracket of claim 1, wherein the main body comprises a rib member configured to provide rigidity to the main body.
6. The support bracket of claim 1, wherein the first extension member further comprises a first end portion extending from an end of the first extension member opposite to the main body and configured to contact the coil of the condensing unit.
7. The support bracket of claim 1, wherein the support bracket is formed from sheet metal.
8. A protective casing for a condenser coil, the protective casing comprising:
- a first inlet grille;
- a second inlet grille;
- a corner post positioned between the first and second inlet grilles; and
- a support bracket comprising: a main body positioned between the corner post and the condenser coil; and a first extension member and a second extension member extending from opposite ends of the main body and configured such that the first extension member is attachable to the first inlet grille and the second extension member is attachable to the second inlet grille.
9. The protective casing of claim 8, wherein the first extension member includes an aperture and the first inlet grille includes a top post, and a fastener is received through the aperture of the first extension member and engaged with the top post to attach the support bracket to the first inlet grille.
10. The protective casing of claim 8, wherein the main body of the support bracket includes a pair of tab members configured to engage with the corner post.
11. The protective casing of claim 10, wherein the tab members hook onto the corner post to secure the support bracket to the corner post.
12. The protective casing of claim 8 further comprising a top cover configured to attach to the corner post and to the support bracket.
13. The protective casing of claim 12, wherein the top cover is configured to attach to the corner post at a first attachment point, to the first inlet grille and the first extension member at a second attachment point, and to the second inlet grille and the second extension member at a third attachment point.
14. The protective casing of claim 8, wherein the first extension member includes a corner portion configured to engage with a first flange on the corner post, and the second extension member includes a corner portion configured to engage with a second flange on the corner post.
15. A method of protecting a coil assembly for a condensing unit, the method comprising:
- securing an inlet grille around an outside of the coil assembly;
- securing a corner post around an outside corner portion of the coil assembly; and
- supporting the inlet grille at a top portion of the inlet grille such that the inlet grille is essentially immobile; and
- supporting the corner post such that the corner post is essentially immobile.
16. The method of claim 15, wherein a support bracket is used to support the inlet grille at the top portion of the inlet grille.
17. The method of claim 16, wherein a fastener is received through an aperture in the support bracket and engaged with a hole in the inlet grille.
18. The method of claim 15, wherein a support bracket is used to support the corner post and a portion of the support bracket attaches to the corner post.
19. The method of claim 15 further comprising:
- positioning a top cover over the coil assembly;
- securing the top cover to the inlet grille; and
- securing the top cover to the corner post.
20. The method of claim 19, wherein securing the top cover to the inlet grille includes positioning a support bracket between the top cover and the inlet grille.
21. The method of claim 19 further comprising:
- shielding the coil assembly from being punctured by a fastener used to secure the top cover to the corner post.
22. The method of claim 21, wherein a support bracket positioned between the corner post and the coil assembly is used to shield the coil assembly.
Type: Application
Filed: Sep 26, 2006
Publication Date: Apr 24, 2008
Applicant: Carrier Corporation (Farmington, CT)
Inventors: Loren D. Hoffman (Indianapolis, IN), Larry D. Burns (Avon, IN), Louis J. Sullivan (Indianapolis, IN), Derek Leman (Brownsburg, IN)
Application Number: 11/527,217
International Classification: F25D 23/12 (20060101);