Foldable Adjustable Air Handler Mount for Storage and Installation
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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 simplified installation and maintenance.
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 consists of a first support beam, second support beam, third support beam, and fourth support beam that can be segmented and folded for compact storage while maintaining structural integrity when assembled.
Solution Approach 2:
The mounting frame transitions from a static fixed structure to a dynamic foldable structure. The support beams are connected through folding mechanisms that allow the frame to change its configuration between deployed and folded states, enabling easy storage and shipping while providing stable support when installed.
2Adaptability or versatility
If a custom mounting frame is designed for each HVAC unit size, then the frame fits perfectly, but the device complexity and manufacturing cost increase
Solution Approach 1:
The mounting frame is designed as a universal structure that can accommodate multiple HVAC unit sizes. The support beams can be adjusted in position and orientation to fit different unit dimensions, eliminating the need for multiple custom-designed frames for different HVAC models.
Solution Approach 2:
The frame incorporates adjustable and foldable support beams that can be configured in multiple positions. This dynamic configuration capability allows a single frame design to adapt to various HVAC unit sizes and shapes, providing versatility without increasing design complexity.
3Strength
If the mounting frame covers the entire HVAC unit for maximum support, then the unit is well-supported, but maintenance access becomes difficult
Solution Approach 1:
The mounting frame uses discrete support beams positioned at strategic locations rather than a continuous covering structure. This segmentation provides adequate structural support while leaving the sides, top, and bottom of the HVAC unit accessible for maintenance activities.
Solution Approach 2:
The support structure is concentrated at critical load-bearing points through strategically positioned support beams, rather than uniformly distributing the structure across the entire unit. This local quality approach provides necessary support strength while maintaining open access to most surfaces of the HVAC unit.
4Strength
If the support beams are made long and rigid for maximum strength, then the frame can support heavy units, but the frame cannot be folded for storage
Solution Approach 1:
The support beams are designed with folding capabilities through hinge connections and telescoping mechanisms. These dynamic features allow the beams to maintain their full length and rigidity when deployed for supporting heavy HVAC units, while enabling the frame to fold into a compact configuration for storage and shipping.
Solution Approach 2:
The support beams incorporate telescoping sections that allow one beam segment to nest within another during folding. This nesting mechanism enables the frame to reduce its overall size for storage while maintaining the full extended length of support beams when assembled for load-bearing applications.
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.