Devices for supporting HVAC condensing units outdoors in high velocity wind zones and methods of manufacture and use thereof
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Solution Overview
Problem
Conventional methods for supporting HVAC condenser units in high velocity wind zones are labor-intensive and prone to delays due to the need for concrete slabs, which can crack during transit and are cumbersome to handle, failing to efficiently meet legal requirements for overturn resistance.
Innovation Solution
A modular support system comprising a plastic shell filled with concrete, where the shell provides both aesthetic appeal and structural support, with a top and bottom portion that secure together after curing, and incorporates forklift slots and ground augers for additional stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a concrete slab is poured in place at the installation site, then the pad provides sufficient weight for overturn resistance, but the construction process is time-consuming and laborious
Solution Approach 1:
The pad is pre-assembled with concrete and reinforcement elements before arrival at the installation site. The top portion and bottom portion are connected with rebar and concrete in advance, so that upon arrival, the pad only requires placement and anchoring rather than on-site construction, significantly reducing installation time while maintaining structural integrity and overturn resistance.
2Ease of operation
If a concrete slab is constructed offsite, then the pad can be transported to the installation site, but the concrete slab may crack during transit
Solution Approach 1:
The pad is divided into two separate portions: a top portion containing the concrete and reinforcement, and a bottom portion serving as the base. This segmentation allows each component to be transported independently without the risk of cracking that would affect a monolithic slab, while still enabling assembly into a complete structural unit at the installation site.
Solution Approach 2:
The pad uses a composite structure combining concrete with steel rebar reinforcement and a polymeric material layer. This composite construction provides both the weight necessary for overturn resistance and the flexibility to withstand transport stresses without cracking, while maintaining structural integrity upon assembly.
3Weight of moving object
If the concrete slab has a foam core to reduce weight, then the pad is less heavy for transit, but the pad becomes cumbersome to handle due to size
Solution Approach 1:
By dividing the pad into top and bottom portions, the overall size and weight of each individual component is reduced, making them easier to handle and transport. The segmentation allows for more manageable dimensions while maintaining the total volume and weight necessary for structural performance when assembled.
4Shape
If the shell provides aesthetic outer surface, then the appearance is improved, but the structural support function may be compromised if concrete cracks
Solution Approach 1:
The pad employs a composite construction with concrete providing structural strength and reinforcement, a polymeric material layer providing flexibility and crack resistance, and a shell providing aesthetic appearance. This multi-material approach ensures that even if the concrete develops minor cracks, the polymeric layer and shell maintain the structural integrity and visual appeal of the pad.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables efficient and stable support for HVAC condenser units in high wind zones, meeting legal requirements for overturn resistance while reducing installation time and handling challenges, and can withstand high winds.
Implementation Method 1
Once the concrete cures, then the top portion and the bottom portion are held together via the concrete, as cured.
Data Source
AI summary
A method comprises: causing a volume of a material in an uncured state to be input into a container; causing a plurality of spikes hosted via a lid to extend into the volume of the material in the uncured state within the container such that the lid closes the container and the lid faces the volume of the material; causing the volume of the material within the container to change from the uncured state to a cured state within the container while the lid is closed such that the volume of the material in the cured state within the container secures the lid to the container via the spikes; and causing an outdoor HVAC condenser unit to rest on the container such that the volume of the material in the cured state within the container extends between the outdoor HVAC condenser unit and the lid.