Flange assembly for air-conditioning units

Abstract

A flange assembly (2) for connecting a duct to an AC unit in a time and cost-efficient manner. The flange assembly (2) has a frame (4), and a plurality of side plates (29, 30) for rotatable connection to the frame (4). The side plates (29, 30) are movable between a first state, in which the side plates are accommodated within the frame, and a second state in which the side plates protrude from the frame. Figure 6 to accompany the abstract. 20 25 27 51 54 03 D ec 2 02 5 F L A N G E A S S E M B L Y F O R A I R - C O N D I T I O N I N G U N I T S 2 0 2 5 2 7 5 1 5 4 0 3 D e c 2 0 2 5 6 / 10 Figure 6 2 4 32 26 27 17 -29- 30 33 30 -29- 32 16 17 61 61 60 6 / 10 2 30 32 4 30 -29- -29- 27 first 61 32 16 61 Y X second 20 25 27 51 54 03 D ec 2 02 5 6 / 1 0 D e c 2 0 2 5 2 0 2 5 2 7 5 1 5 4 0 3 3 0 3 2 6 0 4 2 6 3 0 d e - 2 9 - 1 7 1 7 Z f i r s t 6 1 3 2 6 1 Y 3 3 X s e c o n d

Description

FIELD

[0001] The present invention relates to the connection of ducting to air-conditioning units. In particular, the invention uses a flange assembly configured to mount ducting to the outer casing of an air-conditioning unit (AC unit). It is specifically suitable for connecting ducting to “down discharge” air-conditioning units mounted to the rooftop of buildings. However, it will be understood the invention may be used with other air-conditioning units in different orientations. BACKGROUND

[0002] HVAC (Heating Ventilation and Air-conditioning) systems are a common feature in residential, commercial and industrial buildings. These systems typically include one or more air-conditioning units for heating and cooling the air. Normally air from the AC unit is supplied to rooms or areas throughout the building via ducting. AC units mounted on the roof will usually discharge air directly downwards into an underlying duct extending into the building. These AC units are known as down discharge or down draft rooftop AC units and have a relatively robust outer casing for transport and installation. Once the unit is positioned on the rooftop, the underlying duct into the building is connected to an opening at the bottom panel of the outer casing. Typically, these units are installed on a mounting structure that spaces the bottom panel of the outer casing above the open end of the underlying duct. A connecting section is fitted to connect the opening in the bottom panel to the duct. Fitting the connecting section between the duct and the opening in the bottom panel is more challenging and time consuming than fitting the duct work to other types of AC unit such as “front discharge” or sideside AC units with a protruding flange (sometimes referred as a “spigot”) for convenient attachment to duct work.

[0003] Unfortunately, it is not practical to provide a downward flange or spigot around the base panel opening of a down discharge AC unit. A protruding flange cannot support the weight of the AC unit and can be detrimental to the structural and vibrational integrity during operation. Similarly, a flange protruding beneath the unit is likely to be a hinderance during transit or general operations. For example, lifting the AC unit with a forklift is likely to damage the flange with the tines. 2025275154   03 Dec 2025

[0004] In an effort to address these difficulties, current practice includes supplying individual panels that are fastened onsite to construct the sides of the flange protruding below the base panel once the AC unit is positioned on the mounting structure. Another option provides a separate base structure or base panel with pre-fitted flanges for the connection to the duct work. This requires the installer to fit and secure the base panel of the outer casing before connecting the duct work to the downward flange or spigot.

[0005] In some cases, the installers choose to custom design the connecting section for mounting up the duct work to the opening in the base panel of the outer casing.

[0006] In each case, as the opening in the base panel is a simple cutout, each of the current practices involves a significant amount of time, cost and logistics. SUMMARY OF INVENTION

[0007] At least some embodiments of the present invention address or ameliorate the shortcomings of the existing methods for connecting duct work to an AC system or at least provides a useful alternative.

[0008] In one aspect, the present invention provides a flange assembly for connecting a duct to an AC unit, the flange assembly comprising: a frame; a plurality of side plates for rotatable connection to the frame; wherein the side plates are movable between a first state in which the side plates are accommodated within the frame and a second state in which the side plates protrude from the frame.

[0009] Preferably, the AC unit has an air inlet and an air outlet, the frame has a first part for attachment to either the air inlet or the air outlet of the AC unit, and a second part that accommodates the side plates in the first state and rotatably supports each of the side plates.

[0010] Preferably, the first part and the second part are plate-shaped, the second part extends in a direction substantially perpendicular to the first part at either the inner or outer periphery of the first part. 2025275154   03 Dec 2025

[0011] Preferably, each of the side plates has a main body for attaching the duct, and a connecting wall that connects the side plate to the frame, and connects between the side plates in the second state.

[0012] Preferably, the connecting wall extends along a portion of the second part when in the first state; and further comprises a connecting member for each of the connecting walls respectively to detachably connect the connecting walls to the second portion to hold the side plates in the first state.

[0013] Preferably, the frame is composed of four sides, the main body of the side plate is rectangular in shape, and the connecting wall extends along the short sides of the main body.

[0014] Preferably, a length of the connecting walls, in a direction perpendicular to the longitudinal direction of the second part in the first state, is substantially the same as or shorter than the length of the second part.

[0015] Preferably, two adjacent side plates of the side plates overlap the main body of one side plate and the connecting wall of the other side plate in the second state.

[0016] Preferably, the connecting wall has a protrusion extending towards the second part of the frame,

[0017] the second part has a through hole to accommodate the protrusion, the side plates rotate around the protrusion.

[0018] Preferably, wherein the connecting walls each have a hole positioned to overlay a corresponding hole in the second part when in the retracted configuration for receiving a connecting member.

[0019] Preferably, the connecting walls each have a hole positioned to overlay a corresponding hole in one of the adjacent side plates when in the extended configuration, to receive a connecting member.

[0020] A second aspect of the invention provides an air conditioner comprising: an air inlet for air intake and an air outlet for air blowout; wherein, a flange assembly according to the first 2025275154   03 Dec 2025 aspect of the invention described above, the flange assembly being attached to the air inlet or the air outlet.

[0021] A third aspect of the invention provides a method of transporting and installing an air conditioner comprising: providing an air conditioner with an air inlet for air intake and an air outlet for air blowout / discharge; providing a flange assembly configured for attachment to the air inlet or the air outlet, the flange assembly being in accordance with the first aspect of the invention described above; transporting the air conditioner with the side plates in the first state; and, installing the air conditioned for operation with the side plates in the second state. BRIEF DESCRIPTION OF DRAWINGS

[0022] Preferred embodiments of the invention will now be described by way of example only, with reference to the accompanying drawings, in which:

[0023] Figure 1 is a perspective of a down discharge, reverse cycle air-conditioning unit with a flange assembly according to the invention mounted at the inlet and discharge openings, with both assemblies in the retracted or folded state.

[0024] Figure 2 is a partially exploded perspective of the flange assembly showing the long side panels within the frame without the short side plates.

[0025] Figure 3 is a partially exploded perspective of the flange assembly showing the short side panels overlying the long side plates.

[0026] Figure 4 is a perspective of the assembled flange assembly retracted into the folded state.

[0027] Figure 5 is an enlarged partial perspective of one corner of the flange assembly shown in Figure 4, showing the hinge pins for rotatably attaching the side plates to the frame and fixing points for connecting members (e.g. screws).

[0028] Figure 6 is a perspective of the flange assembly with the long side plates rotating to an extended operational state for installation. 2025275154   03 Dec 2025

[0029] Figure 7A is a perspective of the flange assembly with the short side plates rotating to the operational state for installation.

[0030] Figure 7B is an enlarged partial perspective of an embodiment of the frame assembly with tabs extending from the long side plates for bending over the connecting wall of the short side plates to hold the assembly in the operational state.

[0031] Figure 8 is a perspective of the flange assembly in the operational state for connecting to ductwork.

[0032] Figure 9 is an enlarged partial perspective of one corner of the flange assembly shown in Figure 8, showing the hinge pins for rotatably attaching the side plates to the frame and fixing points for connecting members (e.g. screws) to retain the assembly in the extended or operational state.

[0033] Figure 10 is a perspective of the AC unit of Figure 1 with the flange assemblies in the operational state. DESCRIPTION OF EMBODIMENTS

[0034] Figure 1 illustrates a typical down discharge AC unit 1 with the flange assemblies 2 retracted into the folded state for protection during transport and handling. Fans 27 draw airflow in through an inlet plenum 26 across a coil array for heat transfer to (or from) a working fluid flowing through the coil. Conditioned air is discharged through the outlet plenum 25 and into the ductwork of the building. The AC unit 1 is housed in an outer casing 6 including a base panel 11 held in a relatively sturdy base frame 28. The base frame 28 is robust enough for lifting and moving the unit during transport to site and installation. For example, the base frame 28 can support the weight of the unit and will not be damaged by normal contact with the tines of a forklift.

[0035] The base panel 11 has an opening in the inlet plenum 26 and an opening in the discharge plenum 25. Each of the openings have a flange assembly 2 in the folded state with all side plates (discussed below) encapsulated within the boundaries of the base frame 28. As previously highlighted, the importance of the flange assembly 2 being within the limits of the unit 1 allows efficient transport and logistics, while minimising the risk of damage from transit 2025275154   03 Dec 2025 such as from forklifts tines. In some embodiments, the panels are supplied pre-assembled to eliminate any further packaging, damage or waste that may result from providing the flange assembly 2 separately for onsite assembly. The pre-assembled flange assembly 2 fitted to the AC unit 2 highlights its simplicity over the current practice of a separate base structure fabricated to mount up the ductwork. Using a separate base structure involves a significant amount of time, material usage and cost to assemble. The separate base structure also requires additional transport space and load without additional benefit. [Structure of Flange Assembly]

[0036] Figures 2 to 5 illustrate the process of assembling the flange assembly 2 into a folded state. Here, the specific structure of the flange assembly 2 is described with reference to Figures 2 through 5.The flange assembly 2 includes frame 4 and four side plates 5. The frame 4 serves as a structure connected to the inlet plenum 26 or the discharge plenum 25 of the AC unit 1, and functions both as a housing for the side plates 5 during transportation and as a support for the side plates 5 during operation. During transportation, the flange assembly 2 is in a "folded state," with the side plates 5 folded within the frame 4. When attaching the duct to the AC unit 1, the flange assembly 2 transitions to an "operational state," with the side plates 5 protruding from the frame 4. In the following description of the flange assembly 2, unless otherwise specified, it is assumed the assembly is in the folded state with the side plates 5 folded within the frame 4. The folded state of the flange assembly 2 refers to the condition in which the side plates 5 are folded within the frame 4 wherein, when viewing the flange assembly 2 from either the X-axis or Y-axis, the side plates 5 are housed within the frame 4.

[0037] The frame 4 comprises four sides. In this embodiment, the frame 4 includes two short sides and two long sides, forming a rectangular shape. The frame 4 may form a square shape, having four sides of equal length. The frame 4 includes a first plate member 14 extending in the X-Y axis plane and a second plate member 15 extending in the first direction on the Z-axis perpendicular to the X-Y axis plane, as shown in Figure 2. The first plate member 14 may be integrally formed or may be made of multiple members connected by welding or connecting them together. The second plate member 15 extends in the first direction along Z axis from the inner or outer peripheral edge of the first plate member 14. The second plate member 15, extending from the inner peripheral edge of the first plate member 14, reduces the length of the 2025275154   03 Dec 2025 engaging members connecting the side plate 5 and the frame 4 compared to when it extends from the outer peripheral edge.

[0038] The first and second plate members 14 and 15 may be integrally formed or connected by welding or other suitable methods.. The frame 4 may be steel, aluminum or other extrusions or castings.

[0039] In this embodiment, the four side plates 5 are provided as two long side plates 29 and two short side plates 30. Each long side plate 29 and short side plate 30 are rectangular in shape. Two long side plates 29 are positioned along the two long sides of the rectangular frame 4, while two short side plates 30 are positioned along the two short sides of the rectangular frame 4. The long side of the long side plate 29 that faces the frame 4 is referred to as the first long side 60, whereas the long side opposite to the first long side is designated as the second long side 61. Similarly, the long side of the short side plate 30 that faces the frame 4 is termed the first long side 62, and the long side opposite to the first long side is referred to as the second long side 63. The length of the long side of the long side plate 29 is approximately equal to or less than the length of the long side of the internal perimeter of the frame 4, which is formed by the first plate member 14. Similarly, the length of the long side of the short side plate 30 approximately equal to or less than the length of the internal perimeter of the first plate member 14 constituting the short side of frame 4. The lengths of the short sides of the long side plate 29 and the short side plate 30 are nearly identical. The upper limit of the short side length for both the long side plate 29 and the short side plate 30 should ideally be less than 50% of the short side length of the frame 4, preferably less than 45%, to avoid interference between opposing side plates 5 when folded into frame 4 and to maintain the compactness of the frame assembly 2. Conversely, the lower limit of the short side length should be greater than 10%, ideally greater than 15% of the short side length of the frame 4, to ensure a stable connection to the duct. The short side length of these plates is selected appropriately, based on the material and diameter / width of the connected duct.

[0040] The long side plate 29 comprises a rectangular-shaped main body 291 and a connecting wall 16. The connecting wall 16 extends in the first direction on the Z-axis along both short sides of the main body 291 when the side plate 5 is folded within the frame 4. It is preferable for the main body 291 and the connecting wall 16 to be integrally formed. The connecting wall 16 may be created by bending the edge of a metal sheet of the main body 291, for example. The length of 2025275154   03 Dec 2025 the connecting wall 16 in the Z-axis direction is approximately equal to the length of the second plate member 15 in the same direction. Although the Z-axis length of the connecting wall 16 may be shorter or longer than that of the second plate member 15, it is ideal for them to have the same length or for the connecting wall 16 to be slightly shorter to ensure compact accommodation when the side plate 5 is folded into the frame 4.

[0041] A first protrusion 32 extends from the surface on the frame 4 side of the connecting wall 16 towards the short side of the frame 4 in a vicinity of the first long side 60 of the long side plate 29. The first protrusion 32 is formed on each of the connecting walls 16 at both ends of the long side plate 29. A first through-hole 31 is formed, in a vicinity of the long side of the frame 4, on the short side of the second plate member 15. The first through-hole 31 is formed on each of the short sides of the second plate member 15. The first through-hole 31 allows the first protrusion 32 to penetrate. The penetration of the first protrusion 32 into the first through-hole 31 facilitates the connection of the long side plate 29 to the frame 4. The first protrusion 32 is cylindrical in shape, having a diameter smaller than that of the first through-hole 31. This configuration allows the long side plate 29 to rotate easily relative to the frame 4, employing the first protrusion as an axis 12.

[0042] The connecting wall 16 extends along the short side of the long side plate 29 from the first long side 60 to a midpoint towards the second long side 61. A through-hole 33 is formed in the connecting wall 16 at a position spaced from the first protrusion 32 towards the second long side 61. Additionally, when the side plate 5 is folded within the frame 4, the second plate member 15 constituting the short side of the frame 4 has a through-hole 34 at a position corresponding to that of the through-hole 33 on the connecting wall 16. By passing an engaging member 17, such as a screw, through both the through-hole 33 on the connecting wall 16 and the through-hole 34 on the second plate member 15, the long side plate 29 can be temporarily secured in a folded state with respect to the frame 4.

[0043] As shown in Figure 3, the short side plate 30 comprises a rectangular-shaped main body 301 and a connecting wall 26. The connecting wall 26 extends in the first direction on the Z-axis along both short sides of the main body 301 when the side plate 5 is folded within the frame 4. It is preferable for the main body 301 and the connecting wall 26 to be integrally formed. The connecting wall 26 may be created by bending the edge of a metal sheet of the main body 301, for example. The length of the connecting wall 26 in the Z-axis direction is approximately equal 2025275154   03 Dec 2025 to the length of the second plate member 15 in the same direction. Although the Z-axis length of the connecting wall 26 may be shorter or longer than that of the second plate member 15, it is ideal for them to have the same length or for the connecting wall 26 to be slightly shorter to ensure compact accommodation when the side plate 5 is folded into the frame 4.

[0044] A second protrusion 42 extends from the surface on the frame 4 side of the connecting wall 26 towards the long side of the frame 4 in a vicinity of the first long side 62 of the short side plate 30. The second protrusion 42 is formed on each of the connecting walls 26 at both ends of the short side plate 30. A second through-hole 41 is formed, in a vicinity of the short side of the frame 4, on the long side of the second plate member 15. The second through-hole 41 is formed on each of the long sides of the second plate member 15. The second through-hole 41 allows the second protrusion 42 to penetrate. The penetration of the second protrusion 42 into the second through-hole 41 facilitates the connection of the short side plate 30 to the frame 4. The second protrusion 42 is cylindrical in shape, having a diameter smaller than that of the second through-hole 41. This configuration allows the short side plate 30 to rotate easily relative to the frame 4, employing the protrusion as an axis 22.

[0045] The connecting wall 26 extends along the short side of the short side plate 30 from the first long side 62 to the second long side 63. A through-hole 43 is formed in a vicinity of the second long side 63 of the connecting wall 26. Additionally, when the side plate 5 is folded within the frame 4, the second plate member 15 constituting the long side of the frame 4 has a through-hole 44 at a position corresponding to that of the through-hole 43 on the connecting wall 26. By passing an engaging member 27, such as a screw, through both the through-hole 43 on the connecting wall 26 and the through-hole 44 on the second plate member 15, the short side plate 30 can be temporarily secured in a folded state with respect to the frame 4.

[0046] The first through-hole 31 for the long side plate 29 and the second through-hole 41 for the short side plate 30 may be circular to match the cross-sectional shape of cylindrical protrusions (32, 42). The through-holes (31,41) also may be configured to extend in the longitudinal direction of the second plate member 15. When the through-holes (31,41) extend in the longitudinal direction of the second plate member 15, the shape of the through-holes (31,41) may be oval or consist of two connected circles of different diameters. When the through-holes (31,41) are oval, it facilitates the alignment of the through-holes (33,43) on the connecting walls (16,26) with those (34,44) on the second plate member 15, and further reduces the potential for 2025275154   03 Dec 2025 interference between the first long sides (60, 62) of the side plates 5 and the frame 4 when the side plate 5 rotates around the axis (12,22). When configuring the through-holes (31, 41) to connect two circles of different diameters, the diameter of the first circle may be slightly larger than the diameter of the protrusions (32, 42), while the diameter of the second circle may be larger than that of the first circle. Ideally, the first circle may be positioned on the first long side (60, 62) of the side plates 5, and the second circle on the second long side (61, 63). This arrangement facilitates temporarily securing the side plates 5 in its folded position within the frame 4 without using engaging members (17, 27) by fitting the protrusions (32, 42) into the first circles. When rotating the side plates 5 around the axis (12,22), the projections (32, 42) can be transitioned towards the second circles.

[0047] In the state where the side plates 5 are folded within the frame 4, the short side plate 30 is positioned above the long side plate 29 in the first direction on the Z-axis. To prevent damage during transport, the short side plate 30 and the long side plate 29 are temporarily secured using engaging members, such as screws. Specifically, as shown in Figure 3, multiple through-holes 100 are formed in the main body 291 of the long side plate 29, and corresponding through-holes 200 are also formed in the main body 301 of the short side plate 30 at positions aligning with those in the long side plate 29. The long side plate 29 and the short side plate 30 are temporarily secured by passing the engaging members through these through-holes (100, 200).

[0048] A plurality of through-holes 110 are formed along the first long side 60 of the long side plate 29. When the second long side 61 of the long side plate 29 is displaced in the second direction along the Z-axis, a vicinity of the first long side 60 of the long side plate 29 faces to the inner surface of the long side of the second plate member 15. In this alignment, a plurality of through-holes 151 are formed along the long side of the second plate member 15. The through-holes 151 correspond to the through-holes 110. By passing engaging means such as screws through the through-holes 110 and 151, the long side plate 29 can be maintained in the “operational state”.

[0049] A plurality of through-holes 210 are formed along the first long side 62 of the short side plate 30. When the second long side 63 of the short side plate 30 is displaced in the second direction along the Z-axis, a vicinity of the first long side 62 of the short side plate 30 faces to the inner surface of the short side of the second plate member 15. In this alignment, a plurality of through-holes 152 are formed along the short side of the second plate member 15. The through- 2025275154   03 Dec 2025 holes 152 correspond to the through-holes 210. By passing engaging means such as screws through the through-holes 210 and 152, the short side plate 30 can be maintained in the “operational state”.

[0050] Some of the through-holes 151 may be replaced by second through-holes 41 and through-holes 44 to ensure a secure attachment of the connecting wall 26 of the short side plate 30 to the frame 4. In this embodiment, four out of five through-holes 151 on one long side of the second plate member 15, excluding the middle one, are replaced with second through-holes 41 and through-holes 44. Similarly, some of the multiple through-holes 152 may employ first through-holes 31 and through-holes 34 to securely attach the connecting wall 16 of the long side plate 29 to the frame 4. In this embodiment, four out of five through-holes 152 on one short side of the second plate member 15, excluding the middle one, are replaced by first through-holes 31 and through-holes 34.

[0051] Additionally, near the center of both short sides of the short side plate 30, through-holes 303 are formed to correspond with the through-holes 33 of the connecting wall 16 of the long side plate 29 when the flange assembly 2 is in the operational state. [Method for assembling the flange assembly 2]

[0052] Here, the assembly method for folding the flange assembly 2 into its "folded state" is described referring to Figures 2 to 5. First, as shown in Figure 2, the first protrusions 32 of the long side plate 29 are inserted into the first through-holes 31 of the second plate member 15 to secure the long side plate 29 to the frame 4. The sheet metal side plates 5 are flexible enough to bow (discussed in more detail below). This permits the insertion of one of the first protrusions 32 into one of the first through-holes 31 and the bowing the long side plate 29 temporarily reduces the length dimension enough to permit insertion of the other first protrusion 32 in the opposing first through-hole 31 as the long side plate 29 is allowed to elastically return to its original flat configuration. At this point, if only the first protrusions 32 are inserted into the first through-holes 31, the second long side 61 of the long side plate 29 might move in the second direction along the Z-axis. Therefore, the engaging members 17 such as pins or screws are inserted to the through-holes 33 of the connecting wall 16 and to the through-holes 34 on the short side of the second plate member 15, to maintain the long side plate 29 in a folded state against the frame 4. 2025275154   03 Dec 2025

[0053] Subsequently, the short side plate 30 is provided above the long side plate 29 in the first direction along the Z-axis. Here, the second protrusions 42 of the short side plate 30 are inserted through the second through-holes 41 of the second plate member 15 to secure the short side plate 30 to the frame 4. Similar to the assembly technique used for the long side plate 29 discussed above, the short side plate 30 is flexed into a bowed configuration. This permits the insertion of one of the second protrusions 42 into one of the second through-holes 41 and the bowing the short side plate 30 temporarily reduces the length dimension enough to permit insertion of the other second protrusion 42 in the opposing second through-hole 41 as the short side plate 30 is allowed to elastically return to its original flat configuration. At this point, if only the second protrusions 42 are inserted into the second through-holes 41, the second long side 63 of the short side plate 30 might move in the first direction along the Z-axis. Therefore, the engaging members 27 such as pins or screws are inserted to the through-holes 43 of the connecting wall 26 and to the through-holes 44 on the long side of the second plate member 15, to maintain the short side plate 30 in a folded state against the frame 4.

[0054] Finally, to temporarily secure the long side plate 29 and the short side plate 30, engaging members are used to fix the through-holes 100 on the main body 291 of the long side plate 29 and the through-holes 200 on the main body 301 of the short side plate 30.

[0055] With the above configuration, the side plates 5, which includes the long side plates 29 and the short side plates 30, are folded and secured to the frame 4, while the long side plates 29 and the short side plates 30 are further fixed together. Consequently, the long side plates 29 and the short side plates 30 do not move in the direction along the Z-axis during transport, thereby reducing the risk of damage. [Method for transitioning from the folded state to the operation state]

[0056] Figures 6 to 8 illustrate the assembly of the flange assembly 2 as it transitions from its folded state to its operational state. Initially, the engaging members for fixing the through-holes 100 and the through-holes 200 are removed. Subsequently, upon removing the engagement members 17 that connect the long side plate 29 to the second plate member 15, the second long side 61 of the long side plate 29 shifts in the second direction along the Z-axis, as depicted in Figure 6. Specifically, the second long side 61 of the long side plate 29 rotates in the second direction along the Z-axis, using the protrusions 32 as a pivot. During this rotation, the 2025275154   03 Dec 2025 engagement between the first long side 60 of the long side plate 29 and the inner wall surface of the second plate member 15 positions the long side plate 29.

[0057] Subsequently, upon removing the engagement members 27 that connect the short side plate 30 to the second plate member 15, as shown in Figure 7A, the second long side 63 of the short side plate 30 moves in the second direction along the Z-axis. This movement involves rotation using the protrusions 42 as the pivot, directing the second long side 63 of the short side plate 30 in the second direction along the Z-axis. Through this rotation, the engagement between the first long side 62 of the short side plate 30 and the inner wall surface of the second plate member 15 facilitates the positioning of the short side plate 30.

[0058] Then the second long side 61 of the long side plate 29 and the second long side 63 of the short side plate 30 rotate in the second direction along the Z-axis and both plates are aligned, the connecting wall 16 of the long side plate 29 overlaps with the main body 301 of the short side plate 30, while the connecting wall 26 of the short side plate 30 overlaps with the main body 291 of the long side plate 29. The long side plate 29 and the short side plate 30 are connected by inserting engaging members 18 into the through-holes 33 on the connecting walls 16 and the through-holes 303 of the main body 301. As a result, a double structure is formed at the junction where the short side ends of both the long side plate 29 and the short side plate 30 meet. This design effectively mitigates the leakage of air flowing through the flange and duct from the gap between the long side plate 29 and the short side plate 30.

[0059] As shown in Figure 7B, tabs 64 may be formed at both ends of the second long side 61 of the long side plate 29, extending away from the main body 291. The connection wall 26 of the short side plate 30 extends from the first 62 to the second long side 63, allowing temporary fixing by bending the tab inward when the flange assembly 2 is in the operational state, thereby fixing the connection wall 26 of the short side plate 30 with the main body 291 of the long side plate 29. The side plates 5 should preferably have a thickness of 1mm or less, ideally between 0.95mm and 1mm. This thickness provides adequate rigidity for duct connection while allowing the side plates 5 to be flexed for assembly into the frame 4 (as discussed above), or the tab discussed above bent when fitting into the frame 4. 2025275154   03 Dec 2025

[0060] Finally, to strengthen the connection between the side plates 5 and the frame 4, the through-holes 110 of the long side plate 29 and the through-holes 151 on the long side of the second plate member 15 are secured using fastening members. Similarly, the through-holes 210 of the short side plate 30 and the through-holes 152 on the short side of the second plate member 15 are secured with fastening members. [Method of installation of the flange assembly 2 on the AC unit1]

[0061] Each of the four sides of the first plate member 14, which form a rectangular or square shape, features through-holes. When attaching the flange assembly 2 to the inlet plenum 26 and the discharge plenum 25 of the AC unit 1, the first plate member 14 of the flange assembly 2 is secured to the peripheral edge of the opening of the inlet plenum 26 or the outlet plenum 25. The flange assembly 2 can be mounted either from inside or outside the casing 6 of the AC unit 1. The first plate member 14 and the casing 6 of the AC unit 1 are then fixed together by fastening members.

[0062] In the present embodiment, while the flange assembly 2 is attached to the discharge plenum 25 and / or inlet plenum 26 formed on the bottom panel of the AC unit 1, the flange assembly 2 can also be suitably used even if the discharge plenum 25 and inlet plenum 26 are formed on the side panels of the AC unit 1.

[0063] As previously discussed, sheet metal is used for the side plates 5 of this flange assembly 2 used in a packaged air-conditioning unit 1, however skilled workers will understand various other materials are suitable and may be selected depending on the intended purpose.

[0064] At least some forms of the flange assembly 2 according to invention used with a packaged air-conditioning unit 1 offer significant advantages compared to existing ductwork connection techniques. Furthermore, the benefits apply to both new building ducting systems and the replacement of old packaged air-conditioning systems. As previously discussed, current practices include supplying individual panels that require onsite fastening, or a separate base structure entirely with pre-existing protruding flanges. In some circumstances, the AC unit is manufactured without any mounting flange (and only a simple cutout in the base panel). In each of these situations, additional time and cost is required for installers / customers to fit complex and / or custom designs. Whether the ductwork is pre-existing within a building being re-used, or 2025275154   03 Dec 2025 new ductwork entirely, having a fixed mounting flange provided by the side plates in the extended configuration provides a time and cost-efficient installation. After sealing and insulation of the supplied flange assembly 2, the ductwork can simply attach to it without the need for a complex frame, additional flange or transition piece required to clear the design / dimension constraints of the unit base structure. Furthermore, the interior of the AC unit 1 is better protected from integrity threats by eliminating the need for fastening anything into the base panel itself.

[0065] The invention has been described herein by way of example only. Skilled workers in this field will readily recognise many variations and modifications which do not depart from the spirit and scope of the broad inventive concept.

[0066] Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms a part of the common general knowledge in the field.

[0067] Unless the context clearly requires otherwise, throughout the description and claims, the words “comprise”, “comprising” and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say in the sense of “including, but not limited to”.

[0068] Terms such as “generally” and “about” should be construed by the skilled addressee having regard to normal tolerances in this field of technology.

[0069] It must also be noted that, as used in the specification and the appended claims, the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise.

[0070] Although an example of the disclosed technology is explained in detail herein, it is to be understood that other embodiments are contemplated. Accordingly, it is not intended that their disclosed technology be limited in its scope to the details of construction and arrangement of components set forth in the following description or illustrated in the drawings.

[0071] A feature in the claims stated in general terms will represent a principle of general application, where it is reasonable to expect (i.e., reasonable to predict) that the claimed 2025275154   03 Dec 2025 invention will work with anything that falls within the general term. Such a feature defined in general terms may be a major part of the claim, or it may be a simple descriptive word. In any other case, a feature in the claims expressed in general terms will be sufficiently enabled if the disclosure enables at least one form of, or one application of, a general principle in respect of the feature, and the person skilled in the art would reasonably expect the invention to work with anything that falls within the general term.

[0072] Broadly drafted claims may be considered enabled if, prima facie: a) the disclosure teaches a principle that the person skilled in the art would need to follow in order to achieve each and every embodiment falling within the claim; and b) the specification discloses at least one application of the principle and provides sufficient information for the person skilled in the art to perform alternative applications of the principle in that way, while not explicitly disclosed, would nevertheless be obvious to the person skilled in the art.

Claims

1. A flange assembly for connecting a duct to an AC unit, the flange assembly comprising:a frame;a plurality of side plates for rotatable connection to the frame; whereinthe side plates are movable between a first state in which the side plates are accommodated within the frame and a second state in which the side plates protrude from the frame.

2. A flange assembly according to claim 1, wherein the AC unit has an air inlet and an air outlet,the frame has a first part for attachment to either the air inlet or the air outlet of the AC unit, anda second part that accommodates the side plates in the first state and rotatably supports each of the side plates.

3. A flange assembly according to claim 2, whereinthe first part and the second part are plate-shaped, the second part extends in a direction substantially perpendicular to the first part at either the inner or outer periphery of the first part.

4. A flange assembly according to claim 2 or 3, whereineach of the side plates has a main body for attaching the duct, anda connecting wall that connects the side plate to the frame, and connects between the side plates in the second state.

5. A flange assembly according to claim 4, whereinthe connecting wall extends along portion of the second part when in the first state; andfurther comprisesa connecting member for each of the connecting walls respectively to detachably connect the connecting walls to the second portion to hold the side plates in the first state.

6. A flange assembly according to claim 4 or 5, whereinthe frame is composed of four sides,the main body of the side plate is rectangular in shape, andthe connecting wall extends along the short sides of the main body.2025275154   03 Dec 20257. A flange assembly according to claim 6, whereina length of the connecting walls, in a direction perpendicular to the longitudinal direction of the second part in the first state, is substantially the same as or shorter than the length of the second part.

8. A flange assembly according to claim 6 or 7, wherein two adjacent side plates of the side plates overlap the main body of one side plate and the connecting wall of the other side plate in the second state.

9. A flange assembly according to claim 5, whereinthe connecting wall has a protrusion extending towards the second part of the frame,the second part has a through hole to accommodate the protrusion,the side plates rotate around the protrusion.

10. A flange assembly according to claim 7, wherein the connecting walls each have a hole positioned to overlay a corresponding hole in the second part when in the retracted configuration for receiving a connecting member.

11. A flange assembly according to claim 7, wherein the connecting walls each have a hole positioned to overlay a corresponding hole in one of the adjacent side plates when in the extended configuration, to receive a connecting member.

12. An air conditioner comprising:an air inlet for air intake and an air outlet for air blowout; wherein,a flange assembly according to any one of claims 1 to 11 attached to the air inlet or the air outlet.

13. A method of transporting and installing an air conditioner comprising:providing an air conditioner with an air inlet for air intake and an air outlet for air blowout / discharge;providing a flange assembly configured for attachment to the air inlet or the air outlet, the flange assembly being in accordance with any one of claims 1 to 11;2025275154   03 Dec 2025transporting the air conditioner with the side plates in the first state; and, installing the air conditioned for operation with the side plates in the second state.Daikin Australia Pty LimitedDaikin Industries, Ltd.Patent Attorneys for the Applicant / Nominated Person SPRUSON & FERGUSON

Images