Air Handler Mount
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Solution Overview
Problem
Existing air conditioner systems face challenges in storage, shipping, installation, and maintenance due to their bulky and inflexible designs, which complicate handling and require complex installation processes.
Innovation Solution
A foldable and adjustable mounting frame with sliding extension assemblies and asymmetrical folding mechanisms that allows for easy storage, shipping, and versatile installation on various HVAC unit sizes, featuring leveling indicators and drain pan hangers for efficient installation and maintenance access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a traditional fixed mounting frame is used, then the HVAC unit is securely supported, but the frame is bulky and difficult to store and ship
Solution Approach 1:
The mounting frame is divided into multiple support beams that can be folded relative to each other. The frame includes first and second support beams that can be positioned at different angles, allowing the overall structure to be collapsed into a compact configuration for storage and shipping, while maintaining full functionality when deployed.
Solution Approach 2:
The mounting frame transitions from a static fixed structure to a dynamic foldable structure. The support beams are designed to rotate and fold at connection points, enabling the frame to change its overall volume and shape. This dynamic capability allows the same frame to provide full support when installed and compact storage when not in use.
2Adaptability or versatility
If a custom mounting frame is designed for each HVAC unit size, then the fit is precise, but the device complexity and variety of parts increases
Solution Approach 1:
The mounting frame is designed as a universal support structure that can accommodate multiple HVAC unit sizes and configurations. The adjustable support beams and modular design allow a single frame type to be adapted to different installation scenarios, eliminating the need for multiple specialized frame designs for different unit sizes.
Solution Approach 2:
The adjustable and foldable support beams enable the frame to dynamically adapt its dimensions and configuration. By varying the angle and extension of the support beams, the same frame can be configured to suit different HVAC unit sizes and mounting locations, providing versatility without requiring multiple fixed designs.
3Strength
If the mounting frame covers the entire HVAC unit for support, then the unit is well-supported, but access for maintenance becomes difficult
Solution Approach 1:
The mounting frame uses segmented support beams with gaps between them rather than a continuous enclosing structure. This segmentation provides sufficient structural support through the distributed beam network while leaving open spaces that allow technicians to access different parts of the HVAC unit for maintenance and service operations.
4Strength
If the frame is made rigid to support heavy HVAC units, then the support strength is sufficient, but the frame cannot be folded for storage
Solution Approach 1:
The frame incorporates rigid support beams that maintain structural integrity when deployed, combined with flexible connection points that allow folding. The support beams themselves remain rigid to handle heavy HVAC units, while the connection mechanisms between beams enable the overall structure to be collapsed for storage, achieving both strength and foldability.
Data Source
AI summary
A mounting apparatus comprises a base frame assembly comprising a first fixed length support beam and a second fixed length support beam positioned parallel to one another, separated by a first distance, a first adjustable support beam and a second adjustable support beam positioned perpendicular to the first fixed length support beam, and a third adjustable support beam and a fourth adjustable support beam positioned perpendicular to the second fixed length support beam, wherein the first adjustable support beam and the fourth adjustable support beam are separated by a second distance to the second adjustable support beam and the third adjustable support beam, The first adjustable support beam comprises a first sliding extension assembly, the second adjustable support beam comprises a second sliding extension assembly, the third adjustable support beam comprises a third sliding extension assembly, and the fourth adjustable support beam comprises a fourth sliding extension assembly, wherein each of the first sliding extension the second sliding extension assembly, the third sliding extension assembly, and the fourth sliding extension assembly is extendable to a maximum extension length and to a minimum extension length. The base frame also comprises at least four leveling indicators, wherein a first leveling indicator of the at least four leveling indicators is attached to the first fixed length support beam, a second levelling indicator is attached to the second fixed length support beam, a third levelling indicator is attached to the first adjustable support beam, and a fourth levelling indicator is attached to the third adjustable support beam. The mounting apparatus also comprises a drain pan hanger assembly comprising a first drain pan hanger attached to the first fixed length support beam, a second drain pan hanger attached to the second fixed length support beam, and a third drain pan hanger attached to the adjustable support beams, wherein each of the first drain pan hanger, the second drain pan hanger, the third drain pan hanger, and the fourth drain pan hanger is configured to support a sliding drain pan structure. The mounting apparatus also comprises an asymmetrical folding mechanism comprising a first folding assembly positioned along the first and the fourth adjustable support beams and a second folding assembly positioned along the second and the third adjustable support beams, wherein that the first folding assembly is located proximate to the second fixed length support beam, and the second folding assembly is located proximate to the first fixed length support beam.