ACCESS PORT

Abstract

An apparatus for use with residential, commercial and industrial HVACR air duct systems and equipment, providing a means to quickly, easily and accurately measure and/or test air properties within functioning HVACR systems without having to drill a hole into the duct or equipment wall(s) each time the unit is serviced. The apparatus generally includes a mounting flange for attachment to an air duct or other equipment of an HVACR system and an access port including an opening for insertion of a probe therethrough for taking measurements; a cap is also typically included for sealing the access port during periods of non-use. The opening of the access port is centered and placed over a small hole created by a service technician in the wall of the air duct.

Description

FIELD OF THE INVENTION

The present invention relates generally to measuring and testing air properties within air ducts and equipment of residential and commercial HVACR systems, and more particularly to a re-sealable access port for use in inserting a probe therethrough.

BACKGROUND OF THE INVENTION

It is often desirable for a technician to insert a temperature probe and/or a pressure sensor into an air duct or furnace while testing an industrial, commercial or residential Heating, Ventilation, Air Conditioning and/or Refrigeration (HVACR) system, in order to monitor the temperature and/or air flow quality of the air in the ducts. Previous methods of access to air ducts or other equipment of an HVACR system involve a technician drilling one or more holes through the walls of the air ducts as needed, inserting a probe such as a temperature or pressure/flow measuring sensor, followed by removal of the probe and “closing” the hole with aluminum foil, mastic and/or a heavy duet tape that both seals the hole and blends in with the metallic color of the air duct or vent.

The next service technician typically does not see (and/or does not even search for) the covered hole, for such reasons as the holes are typically drilled in unlit and enclosed spaces, the aluminum-colored duct tape is difficult to find, the mastic covering the previous hole requires that a new hole be drilled, and/or the previous holes may be in inconspicuous locations. As a result, the previous holes are never uncovered, and the next technician will simply drill another hole for insertion of a probe each time the HVACR unit is serviced. Further, if the previous holes are not properly sealed, then there may be leakage through the air ducts which can harm the HVACR system.

In light of the continuing need to monitor the air within ducts and other equipment of HVACR systems, it would be desirable to install one or more re-usable access ports at various locations about the system in order to measure parameters such as the air temperature, pressure, or an air pressure drop within the system. It would also be useful for an HVACR service technician to be able to quickly, easily and accurately measure and/or test air properties within functioning air ducts without having to drill a new hole into the duct(s) each time the unit is serviced. It would also be advantageous to provide a re-sealable access port for use in inserting a probe into the duct for periodic testing of the air quality. Other features and advantages of the present invention will become more apparent with reference to the accompanying specification and claims.

SUMMARY OF THE INVENTION

The present invention is an access port for use with industrial, commercial and residential HVACR air duct systems, including furnace, air conditioning and refrigeration systems, providing the ability to periodically access, measure and test air flow properties by inserting a probe through the access port and into the air duct or other equipment of an HVACR system to be tested.

A first aspect of the invention provides an apparatus for use with HVACR air duct systems, the apparatus comprising: (a) a mounting flange for attachment to an air duct or other equipment of an HVACR system; and (b) an access port including an opening for insertion of a probe therethrough, wherein the mounting flange is attached to the air duct so that the opening provides access through a hole in the wall of the air duct.

Another aspect of the invention provides an apparatus for use with HVACR air duct systems, the apparatus comprising: (a) a mounting flange for attachment to an air duct or other equipment of an HVACR system; (b) an access port including an opening for insertion of a probe therethrough; and (c) a cap for sealing the access port, wherein the mounting flange is attached to the air duct so that the opening provides access through a hole in the wall of the air duct.

Another aspect of the invention provides an apparatus for use with HVACR air duct systems, the apparatus comprising: (a) a mounting flange for attachment to an air duct or other equipment of an HVACR system; (b) an access port including an opening for insertion of a probe therethrough, wherein the mounting flange is attached to the air duct so that the opening provides access through a hole in the wall of the air duct; and (c) a cap for sealing the access port, wherein the access port further includes a circular wall that forms a shaft around the opening and that can sealingly fit with the cap, and wherein the cap includes a connecting strip attaching the cap to the mounting flange, thereby allowing the cap to be removed from the access port while remaining attached to the apparatus.

The apparatus of the present invention provides a means to quickly, easily and accurately measure and/or test air properties within functioning air ducts and other equipment of HVACR systems without having to drill a new hole each time the unit is serviced. The nature and advantages of the present invention will be more fully appreciated from the following drawings and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the principles of the invention.

FIG. 1 is a top schematic view of a single piece embodiment of the apparatus of the present invention.

FIG. 2 is a side view of the embodiment of FIG. 1.

FIG. 3 is a bottom view of the embodiment of FIG. 1.

FIG. 4 is an exploded view of a multiple piece embodiment of the apparatus of the invention.

FIG. 5 is a schematic view from below, of the embodiment of FIG. 4.

FIG. 6 is a plan view showing placement of the embodiment of FIG. 4 over a hole in an air duct.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the terms “HVACR systems” or “HVACR air duct systems” means air duct systems and equipment relating to industrial, commercial and/or residential heating, ventilation, air conditioning and/or refrigeration (HVACR) systems, including furnace systems. The present invention remedies the scenario in which multiple holes are drilled into the air ducts or other equipment of an HVACR system over time, and provides a re-usable and re-sealable access port for attachment to air ducts, vents, furnaces or other equipment of HVACR systems. Temperature probes, pressure sensors/probes and the like can be inserted through the access port any time a service technician is required to do so.

With reference to FIGS. 1-3, the present invention is an apparatus 10 for attachment to an air duct or other equipment of an HVACR system which includes a mounting flange 12 having an access port 16 for insertion of a probe therethrough. A circular access port 16 having an opening 18 is typically centered within a typically circular mounting flange 12 as shown; however these elements can be in any shape desired, so long as the apparatus can allow a probe to be inserted therethrough. As illustrated, the access port typically includes a circular wall 16 surrounding the opening 18, with the circular wall 16 creating a shaft around the opening 18 and being capable of sealingly fitting with a cap 24. The opening shown in FIGS. 1 and 3 is a cross-hatched (or cross-hair) cutout 18; however, any type of opening is envisioned, including a simple small hole through the mounting flange (39, see FIG. 5), so long as the opening is large enough for insertion of a probe therethrough, and which can be re-sealed with a cap or the like to provide proper duct wall integrity after the probe is removed.

The cap 24 is typically included with and attached to the mounting flange 12, for sealing the opening 18 of the access port during periods of non-use. As shown in FIG. 2, the cap 24 can include a plug 26 to seal the opening 18, and the circular wall 16 can include an optional sealing ridge 17 to create a stronger seal with the cap 24. The cap 24 can also include a pull tab 28 for use in removing a cap that is currently sealed to the circular wall 16, and a pull tab hole 30 can also be included if desired for use in threading a string, wire or other gripping device therethrough for adding a mechanical advantage to manipulation of the cap during removal from the opening 18.

As shown in FIGS. 1-3, a connecting strip 20 can be included with the mounting flange 12 and access port 16 so that the cap 24 is permanently attached to the mounting flange 12. As shown in FIG. 2, the connecting strip 20 attaches at its proximal portion to the circular wall 16 of the mounting flange, and at its distal portion to the cap 24; however, the proximal portion of the connecting strip 20 can be attached to any part of the mounting flange 12. Thus, the cap 24 can be removed from the access port 16 when a service technician is taking measurements, while remaining attached to the mounting flange 12 so that it can be quickly located and not dropped onto a dark floor and lost forever. As seen in FIG. 1, the cap 24 can also include a plug 26 that seals the opening 18. In the embodiment shown in FIG. 1, the plug 26 fills the shaft created by the circular wall 16.

A step up flange 14, shown in FIGS. 1 and 2 (and as 34 in FIG. 4) can be included as a raised portion of the mounting flange for providing structural support to the opening 18. In embodiments in which a circular wall 16 is part of the access port, the step up flange abuts, and is actually part of the outer diameter of the circular wall 16. The step up flange 12 can form a supportive base for the shaft created by the circular wall 16, making the apparatus more supportive in the area around the opening 18 of the mounting flange 12. While the access port typically includes a circular wall 16 to which the cap 24 is sealed, it can be envisioned that the wall created by the step up flange 14, as it is a raised portion of the mounting flange 12 surrounding the opening 18, can also be used for sealing the cap 24 to the mounting flange 12. In such an embodiment, the outer diameter of the cap 24 can sealingly fit within the wall created by the step up flange 14 as it surrounds the opening 18.

FIGS. 4 and 5 illustrate an embodiment 50 of the invention wherein the apparatus 50, including a mounting flange 32, a disc 35 including a cross-hatched cutout opening 38, and a cap 44 can be manufactured in multiple connecting pieces. As shown, the mounting flange 32 is made as a single piece, and includes a circular wall 36 surrounding an opening 39 (see FIG. 5) through the mounting flange 32 for insertion of a probe therethrough. The circular wall 36 can include a sealing ridge 33 to create a stronger seal with the cap 44. The cap 44 is also made as a single piece, and includes a connecting strip 40 with a distal retaining ring 47 that fits over a retaining barb 37 on the circular wall 36 of the mounting flange 32. The retaining ring 47 can be used to keep the cap 44 attached to the mounting flange 32, both of which are manufactured as single, separate pieces. The cap 44 can also include a pull tab 48, as shown, for gripping use in removing a cap that is currently sealed.

As best seen in FIG. 5, the underside of the mounting flange 32 can receive another single connecting piece, an insertable disc 35, from below. The disc 35 can include a cross-hatched cutout as an opening 38, and fills the opening 39 of the access port by fitting into an insert disc relief pocket 49. The relief pocket 49 can be coincidental in diameter with the step up flange 34 of the mounting flange 32. The disc 35 can be inserted into the relief pocket 49 and thus cover the opening 39 at the underside of the mounting flange 32.

As illustrated in FIG. 6, to properly affix the apparatus to an air duct A, the access port including the circular wall 36 and the opening 39 of the mounting flange 32 (with or without the disc 35 having been inserted into the relief pocket) is centered over the hole 60 in the wall of the air duct A, and the mounting flange 32 is then pressed in the direction of the arrows pointing to the air duct A. It is contemplated that the apparatus 50 of FIGS. 4 and 5 can be attached to the air duct with or without the disc 35. The cap 44 covers the opening 39 by sealingly fitting with the circular wall 36 of the mounting flange 32.

The mounting flange 12, 32 shown in FIGS. 1-6 typically has an adhesive on the back covered by a protective sheet which the technician can peel off prior to attaching the mounting flange to the wall of the air duct. Such adhesive means are well-known in the art. The adhesive is typically permanent, but a temporary adhesive or even a magnetic attachment of the mounting flange to the wall of the air duct is contemplated. Pressure can be applied and the mounting flange can be affixed to the air duct, with the opening centered over the hole in the wall of the air duct. This allows the apparatus 10, 50 to remain on the air duct and provide a re-usable site which can be easily recognized as the place to take air duct readings. This can also ease the mind of the home owner, knowing that no more holes need to be drilled into their HVACR system.

Typical ventilation ducts are made of sheet metal, but may be made of several different types of materials, such as, but not limited to sheet metal with insulation, duct board, wall board, etc. In some cases, the sheet metal may range from approximately 18 gauge thickness to 26 gauge thickness (or approximately 0.05 inches to 0.0187 inches). The technician may take advantage of a pre-drilled hole (if one exists) or drill a new hole, which will be covered with the apparatus. For purposes of the present invention, a “hole” (60, FIG. 6) can be either a pre-drilled hole or a new hole that is drilled either before or after the mounting flange 12, 32 is affixed to the air duct A, over which the access port opening 18, 39 is centered. A cap 24, 44 can be placed over the access port when the apparatus is not being used by a service technician, to seal the access port leading to the hole 60 in the air duct A.

Typically the hole 60 drilled in the air duct A is small, yet large enough for a shaft of a typical temperature probe or pressure sensor to be inserted therethrough by an HVACR service technician. Types of probes and/or test instruments for use with the present invention can include, but are not limited to: temperature thermocouples (ranging from small wire type to probe style), airflow measuring devices such as a hotwire anemometer, instruments that measure humidity, instruments that calculate wet bulb based on temperature and humidity, instruments that calculate target delta T, instruments that target evaporator exit temperatures, instruments that measure static pressures in the duct or furnace, instruments that measure O₂, CO₂, carbon monoxide or other elements in the air, instruments used to visually inspect the duct, evaporator coil, furnace heat exchanger or for other HVACR elements abnormalities. Brand names can include UEI, Fluke, Fieldpiece, Testo, Bacharach, Dwyer, Rigid, Flir and more.

All of the elements of the access port of the present invention are typically made of a generally soft, molded material such as soft plastic, silicone, rubber or a combination thereof. The apparatus can be manufactured as either a single unit (see FIGS. 1-3) or in multiple connecting pieces or units (see FIGS. 4 and 5). As a non-limiting example, the cross-hair or cross-hatched section (as well as the rest of the apparatus) can be preformed from any suitable material having sufficient resilience such that it is flexible yet returns to its initial configuration, e.g. the flaps of the cross-hatched section reversibly bending upon insertion of a probe therethrough. Flexible thermoplastic materials such as polyvinylchloride, polyethylene, or the like are preferred materials meeting the above requirements.

The present invention may be suitable for installation in a variety of HVACR equipment and air duct systems, including furnaces, air conditioning and refrigeration systems. In some cases, it may be necessary to perform a differential pressure test by inserting probes at various locations about the system. As a non-limiting example, the technician can place a first access port in the return (incoming) air duct and a second access port in the supply (outgoing) air duct. An access port can also be placed, for example, for access to the housing of a furnace, heating coils or other equipment connected with the HVACR system. While the access port of the invention is described in the context of HVACR systems and ventilation ducts, it is contemplated the inventive apparatus may be used in a variety of applications where parameter sensing is desired.

While the present invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will be readily apparent to those skilled in the art. Accordingly, departures may be made from such details without departing from the scope of the invention.

Claims

1. An apparatus for use with HVACR air duct systems, the apparatus comprising:

a) a mounting flange for attachment to an air duct or other equipment of an HVACR system; and

b) an access port including an opening for insertion of a probe therethrough, wherein the mounting flange is attached to the air duct so that the opening provides access through a hole in the wall of the air duct.

2. The apparatus of claim 1, wherein the opening includes a cross-hatched cutout for insertion of the probe therethrough.

3. The apparatus of claim 1, wherein the mounting flange includes a step up flange for providing structural support to the access port.

4. The apparatus of claim 1, further comprising a cap for sealing the access port.

5. The apparatus of claim 4, wherein the access port further includes a circular wall forming a shaft around the opening, and wherein the circular wall sealingly fits with the cap.

6. The apparatus of claim 5, the cap further including a plug for sealing the shaft created by the circular wall.

7. The apparatus of claim 4, wherein the cap includes a connecting strip attaching the cap to the mounting flange, thereby allowing the cap to be removed from the access port while remaining attached to the apparatus.

8. The apparatus of claim 4, wherein the apparatus is manufactured as a single unit.

9. The apparatus of claim 4, wherein the apparatus is manufactured in multiple connecting pieces.

10. An apparatus for use with HVACR air duct systems, the apparatus comprising:

a) a mounting flange for attachment to an air duct or other equipment of an HVACR system;

c) an access port including an opening for insertion of a probe therethrough; and

b) a cap for sealing the access port, wherein the mounting flange is attached to the air duct so that the opening provides access through a hole in the wall of the air duct.

11. The apparatus of claim 10, wherein the opening includes a cross-hatched cutout for insertion of the probe therethrough.

12. The apparatus of claim 10, wherein the mounting flange includes a step up flange for providing structural support to the access port.

13. The apparatus of claim 10, wherein the access port further includes a circular wall forming a shaft around the opening, wherein the circular wall sealingly fits with the cap.

14. The apparatus of claim 13, the cap further including a plug for sealing the shaft created by the circular wall.

15. The apparatus of claim 10, wherein the cap includes a connecting strip attaching the cap to the mounting flange, thereby allowing the cap to be removed from the access port while remaining attached to the apparatus.

16. An apparatus for use with HVACR air duct systems, the apparatus comprising:

a) a mounting flange for attachment to an air duct or other equipment of an HVACR system;

b) an access port including an opening for insertion of a probe therethrough, wherein the mounting flange is attached to the air duct so that the opening provides access through a hole in the wall of the air duct; and

c) a cap for sealing the access port, wherein the access port further includes a circular wall that forms a shaft around the opening and which can sealingly fit with the cap, and wherein the cap includes a connecting strip attaching the cap to the mounting flange, thereby allowing the cap to be removed from the access port while remaining attached to the apparatus.

17. The apparatus of claim 16, the cap further including a plug for sealing the shaft created by the circular wall.

18. The apparatus of claim 16, the mounting flange comprising a step up flange for providing structural support to the access port.

19. The apparatus of claim 16, wherein the apparatus is manufactured as a single unit.

20. The apparatus of claim 16, wherein the apparatus is manufactured in multiple connecting pieces.