Cross-Reference To Related Applications

[0001] This application claims the benefit of Australian Provisional Patent Application No. 2014903564 filed 8 September 2014, and the benefit of Australian Provisional Patent

Application No. 2015900648 filed 24 February 2015, each of which are incorporated herein by reference.

Technical Field

[0002] The present invention relates to an air conditioner. In a particular form the present invention relates to a wall (i.e. indoor) unit for an air conditioner.

Background of the Invention

[0003] An air conditioner of the type commonly referred to as a "window and wall air conditioner" (hereinafter a 'wall air conditioner unit'), is a self-contained air-conditioning unit, so called because it is adapted for mounting in window frames, and through openings provided in exterior walls of a building.

[0004] Replacement wall air conditioners units are becoming increasingly difficult to source as split systems and evaporative air coolers are increasingly favoured for their superior efficiency. Moreover, many of the available wall air conditioners units do not meet impending energy efficiency standards.

[0005] Another reason that split system air conditioners are favoured over

wall air conditioning units is because the separation of the compressor into an externally located unit makes for a substantially quieter air conditioning system. Evaporative air coolers are also substantially quieter as they do not feature a compressor in their design.

[0006] Where a wall air conditioner unit was mounted by way of a through hole in an exterior wall of a building, this poses a further problem, as replacement systems don't require the large through hole left by the wall air conditioner.

[0007] It is against this background and the problems and difficulties associated therewith that the present invention has been developed. [0008] Certain objects and advantages of the present invention will become apparent from the following description, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed.

[0009] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is solely for the purpose of providing a context for the present invention. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application.

[0010] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

[0011] In this specification, a statement that an element may be "at least one of a list of options is to be understood that the element may be any one of the listed options, or may be any combination of two or more of the listed options.

Summary of the Invention

[0012] According to a first aspect, there is provided a wall unit for an air conditioning system, said wall unit being adapted for installation in a through opening provided in an exterior wall of a building which has been vacated by a wall air conditioner unit, wherein internals for the wall unit are substantially housed within the wall's through opening and between interior and exterior surfaces of the wall.

[0013] In one form, the wall unit comprises a front, which in use, is substantially flush with the interior surface of the exterior wall.

[0014] In one form, the front comprises an outwardly directed perimeter flange, which in use, extends adjacent to an interior surface of the exterior wall and conceals any edges of the through opening in the interior surface of the exterior wall. [0015] In one form, the air conditioner further comprises a mounting for the wall unit, said mounting being adapted both for insertion in the through opening, and for supporting the wall unit.

[0016] In one form, the mounting comprises a through opening for nesting the wall unit.

[0017] In one form, the wall unit comprises a removable back comprising a back panel, which in use, is substantially flush with an exterior surface of the exterior wall.

[0018] In one form, the removable back is adapted for engagement with, and positioning relative to, a remainder of the wall unit. In this way the distance between the front and the back panel is adjustable to match a thickness of the exterior wall.

[0019] In one form, the back panel comprises an outwardly directed perimeter flange, which in use, extends adjacent to the exterior surface of the exterior wall and conceals any edges of the through opening in the exterior surface of the exterior wall.

[0020] In one form, the air conditioning system is a split system air conditioner further comprising an outdoor unit which is operatively associated with the indoor unit.

[0021] In one form, the indoor unit comprises at least an indoor heat exchanger and a fan.

[0022] In one form, the outdoor unit comprises at least an outdoor heat exchanger, a fan, and a compressor.

[0023] In one form, when the split system air conditioner is acting as an air cooler, the indoor heat exchanger acts as an evaporator, and the outdoor heat exchanger acts as a condenser.

[0024] In one form, when the split system air conditioner is acting as an air heater, the indoor heat exchanger acts as a condenser, and the outdoor heat exchanger acts as an evaporator.

[0025] In one form the air conditioning system is an evaporative air cooler system.

[0026] According to a further aspect, there is provided a split system air conditioner comprising an indoor unit adapted for installation in a through opening provided in an exterior wall of a building for mounting of a wall air conditioner unit, the wall unit comprising a front comprising an outwardly directed perimeter flange, wherein in use, the perimeter flange of the installed indoor unit extends adjacent to an interior surface of the exterior wall and conceals any edges of the through opening in the interior surface of the exterior wall.

[0027] According to a further aspect, there is provided a wall unit for an air conditioning system, said wall unit being adapted for installation in a through opening provided in an exterior wall of a building which has been vacated by a wall air conditioner unit, the wall unit comprising a front, which in use, is substantially flush with the interior surface of the exterior wall.

[0028] According to a further aspect, there is provided a split system air conditioner comprising a wall unit adapted for installation in a through opening provided in an exterior wall of a building which has been vacated by a wall air conditioner unit, wherein internals for the wall unit are substantially housed within the wall's through opening and between interior and exterior surfaces of the wall.

[0029] According to a further aspect there is provided an evaporative air cooler comprising a wall unit adapted for installation in a through opening provided in an exterior wall of a building which has been vacated by a wall air conditioner unit, wherein internals for the wall unit are substantially housed within the wall's through opening and between interior and exterior surfaces of the wall.

[0030] A detailed description of one or more embodiments of the invention is provided below along with accompanying figures that illustrate by way of example the principles of the invention. While the invention is described in connection with such embodiments, it should be understood that the invention is not limited to any embodiment. On the contrary, the scope of the invention is limited only by the appended claims and the invention encompasses numerous alternatives, modifications and equivalents. For the purpose of example, numerous specific details are set forth in the following description in order to provide a thorough understanding of the present invention.

[0031] The present invention may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so that the present invention is not unnecessarily obscured. Brief Description of the Drawings

[0032] An example of the invention will now be described with reference to the

accompanying drawings, in which:

Figure 1 illustrates both a cross-sectional view through an external wall of a building, and a schematic of a wall air conditioner unit mounted in a through opening in the wall;

Figure 2 illustrates both a cross-sectional view through an external wall of a building, and a schematic of a split system air conditioner comprising a wall unit mounted in a through opening in the wall;

Figure 3 is a schematic cross-sectional view of the wall unit from the split system air conditioner of Figure 2;

Figure 4 is a front view of the wall unit of Figure 3;

Figure 5 is a schematic rear view of the wall unit of Figure 3;

Figure 6 illustrates both a cross-sectional view through an external wall of a building, and a schematic of a split system air conditioner according to a further embodiment, comprising a wall unit mounted in a through opening in the wall;

Figure 7 is a schematic cross-sectional view of the wall unit from the split system air conditioner of Figure 6;

Figure 8 is a schematic front view of the wall unit of Figure 7;

Figure 9 illustrates both a cross-sectional view through an external wall of a building, and a schematic of an evaporative air cooler comprising a wall unit mounted in a through opening in the wall;

Figure 10 is a schematic cross-sectional view of the wall unit from the evaporative air cooler of Figure 9;

Figure 11 is an isometric view of the wall unit from the evaporative air cooler of

Figure 9;

Figure 12 is a front view of the wall unit of Figure 9; and

Figure 13 is a rear view of the wall unit of Figure 9.

Description of the Preferred Embodiments

[0033] Referring to Figure 1, where there is shown a wall air conditioner unit 100 of the prior art, installed in a through opening 6 provided in an exterior wall 8 of a building, and having significant exterior overhang. [0034] Referring now to Figure 2, where there is shown a split system air conditioner 1 according to the present invention, the split system air conditioner 1 comprising a wall unit 2 installed via a mounting 4 in the through opening 6 vacated by the wall air conditioner unit 100 of Figure 1. The split system air conditioner 1 further comprises an outdoor unit 10.

[0035] The mounting 4 comprises a bottom 12, a top 14, and a pair of opposing sides 16 cooperatively defining a passageway 18 through the mounting 4 which is of a rectilinear cross- sectional shape.

[0036] The mounting 4 is sized to nest in and substantially fill the through opening 6 provided in the exterior wall 8 of the building which was vacated by the wall air conditioner 100. The mounting 4 is secured to the wall using fasteners, which can be driven through at least the bottom 12 of the mounting 4 and into a frame for the through opening 6.

[0037] The wall unit 2 comprises a generally cuboid housing 20, an aesthetically pleasing front 30, a pair of sides 22, a top 24, a bottom 26, and a removable back 40. With reference to Figure 3, it can be seen that the housing 20 houses at least an indoor heat exchanger 42 and a fan 44 for circulating air over surfaces of the indoor heat exchanger 42. The front 30 comprises a front panel comprising an air intake 32, and an air outlet 34 for the conditioned air, both of which are covered by a pivoting louver therefor. The front panel 30 further comprises an outwardly extending perimeter flange 36.

[0038] The housing 20 for the wall unit 2 is sized to nest in the mounting 4 with an easy sliding fit. With the back 40 (which comprises a back plate in this embodiment) removed, the wall unit 2 can be inserted into the mounting 4 and slid until the permitter flange 36 abuts, and is substantially flush with, an interior surface of the wall 8.

[0039] In use, the front's 30 outwardly extending perimeter flange 36 extends adjacent to an interior surface of the wall 8 (as illustrated in Figure 2) and conceals any edges of the through opening 6 in the interior surface of the wall 8.

[0040] The back 40 comprises a panel 42 and a collar 44 for insertion into housing 20 of the wall unit 2. The panel 42 comprises an outwardly extending perimeter flange 46. [0041] Once the wall unit 2 has been installed in the mounting 4, the back 40 can then be refitted so that the back plate 42 abuts, and is substantially flush with, an exterior surface of the exterior wall 8 (as illustrated in Figure 2) so that this conceals any edges of the through opening 6 in the exterior surface of the wall 8, and then secured with respect to the housing 20 via screws, thereby securing the wall unit 2 in the through opening 6.

[0042] The back plate 42 comprises apertures through which the refrigerant lines 13 (and power lines) can be passed and connected to the outdoor unit 10.

[0043] The outdoor unit 10 is operatively associated with the wall mounted unit 2 by way of cabling and refrigerant lines 13 extending from the outdoor unit 10 to the back 40 (i.e. external side) of the wall unit 2, where these cables and refrigerant lines 13 are covered with a vanity cover 14. The outdoor unit 10 comprises a housing for an outdoor heat exchanger, a fan for circulating air over surfaces of the outdoor heat exchanger, and a system refrigerant compressor.

[0044] Referring now to Figures 6 through 8, which illustrate an additional embodiment of the invention. Since most of the parts of the split system air conditioner 200 shown in Figures 6 through 8 are identical to corresponding parts shown in the split system air conditioner 1 of Figures 2 through 5, they are denoted by the same reference numerals and will not be described again in detail.

[0045] Split system air conditioner 200 differs from split system air conditioner 1 of Figures 2 through 5 in that it comprises a mounting 4A which will project from the exterior surface of the exterior wall. Split system air conditioner 200 further comprises a back panel 40A which is removably securable to the mounting 4A. The mounting 4A surrounds connections 202 and 204 for the cabling and refrigerant lines 12 respectively. These connections 202 and 204 are accessible by removal of the back panel 40A, and once connection is completed, the back panel 40A can be secured to the mounting 4A to conceal the connections 202 and 204.

[0046] Referring to Figure 9, where there is shown an evaporative air cooler 301, the evaporative air cooler 301 comprising a wall unit 302 installed via a mounting 304 in the through opening 6 vacated by the wall air conditioner unit 100 of Figure 1. The evaporative air cooler 301 further comprises an exterior section 310 which is removably mounted on the back of the wall unit 302. [0047] The mounting 304 comprises a bottom 312, a top 314 and opposing sides 316 cooperatively defining a passageway 318 through the mounting 304 which is of a rectilinear cross-sectional shape.

[0048] The mounting 304 is sized to nest in and substantially fill through opening 6 provided in the exterior wall 8 of the building which was vacated by the wall air conditioner 100. The mounting 304 is secured to the wall using fasteners, which can be driven through at least the bottom 312 of the mounting 304 and into a frame for the through opening 6.

[0049] The wall unit 302 comprises a generally cuboid housing 320, an aesthetically pleasing front 330, a pair of sides 322, a top 324, a bottom 326, and back 340. With reference to Figure 10, it can be seen that the housing 320 houses at last an axial motor 342 for driving a fan 344 for circulating air. The front 330 comprises a front panel comprising an air outlet 334 for the cooled air and a fan speed control 332. The front panel 330 further comprises an outwardly extending perimeter flange 336.

[0050] The housing 320 for the wall unit 302 is sized to next in the mounting 304 with an easy sliding fit. The wall unit 302 can be inserted into the mounting 304 and slid until the perimeter flange 336 abuts, and is substantially flush with, an interior surface of the wall 8.

[0051] In use, the front's 30 outwardly extending perimeter flange 36 extends adjacent to an interior surface of the wall 8 (as illustrated in Figure 10) so that this conceals any edges of the through opening 6 in the exterior surface of the wall 8, and then secured with respect to the housing 320 via screws, thereby securing the wall unit 302 in the through opening 6.

[0052] The back 340 of the wall unit 302 is configured to engage with the exterior section 310 of the evaporative air cooler 301. The exterior section 310 form factor is larger than that of the wall unit 302.

[0053] Once the wall unit 302 has been installed in the mounting 304, the exterior section 310 can then be fitted so that it abuts and projects to a minimal extent from, an exterior surface of the wall 8 (as illustrated in Figure 10) so that this conceals any edges of the through opening 6 in the exterior surface of the wall 8. [0054] The exterior section 310 is operatively associated with the wall unit 302 by way of ducting. The exterior section 310 comprises a housing for at least a water distribution system, cooling pad and associated plumbing and ducting.

[0055] It will be apparent from all of the above that the present invention provides an air conditioning system and a wall unit therefore, which solve the problem of how to fill the opening vacated by a wall air conditioner unit, by replacing it with a system which is aesthetically pleasing and easy to retro fit, which provides at least cooling to current and proposed MEPS (Aust) and EER (USA) legislated energy efficiency standards, which operates with reduced noise and power (running) costs.

[0056] Throughout the specification and the claims that follow, unless the context requires otherwise, the words "comprise" and "include" and variations such as "comprising" and

"including" will be understood to imply the inclusion of a stated integer or group of integers, but not the exclusion of any other integer or group of integers.

[0057] It will be appreciated by those skilled in the art that the invention is not restricted in its use to the particular application described. Neither is the present invention restricted in its preferred embodiment with regard to the particular elements and/or features described or depicted herein. It will be appreciated that the invention is not limited to the embodiment or embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the invention as set forth and defined by the following claims.

[0058] Some embodiments of the invention may utilise 3D printing for construction of the device. Accordingly, in some embodiments the present invention may reside in a digital blueprint comprising a digital file in a format configured for use with rapid prototyping and computer aided design (CAD) and/or manufacturing, such as being in the STL

(stereolithography) file format. Such digital blueprint files, whether produced by performing a three dimensional scan of an embodiment of the invention, or produced by a CAD development software tool, or the like, are within the scope of the present invention.