COMBINED ELECTRICAL AND REFRIGERANT LINESET

Description

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Ser. No. 63/732,965, filed Oct. 15, 2024. This application is herein incorporated by reference, in its entirety, for all purposes.

FIELD OF THE DISCLOSURE

The following disclosure relates generally to Heating, Ventilation, and Air Conditioning (HVAC), and, more specifically, to electrical and refrigerant conduits and insulation used in installing ductless, mini-split air-conditioning systems.

BACKGROUND

Heating, Ventilation, and Air Conditioning (HVAC) systems come in one of two major varieties, ducted, or ‘central,’ and ductless, which are commonly referred to as ‘mini-splits.’ While traditional, central HVAC systems have utilized ductwork to convey heated and/or cooled air around a premises from a central, cooled evaporator, ductless, mini-split HVAC systems do away with the ductwork and rely on a single point of ingress for the conditioned air, which is typically wall, floor, or ceiling-mounted. In other respects, ductless, mini-split systems are very similar to central air conditioning systems in that they have indoor and outdoor units, such as that depicted in FIG. 1, that rely on a compressor, condensing coil, evaporator coil, and fan to condition a home's air.

The ductless, mini-split market has grown significantly in the U.S. over the last 25 years. What was once a fringe product, used only for apartments and converted buildings lacking central air, has become a prominent subset of the HVAC world. This is, in part, because mini-splits are more energy efficient and quieter than traditional air conditioning systems since the introduction of the inverter-based compressor while also being much easier to install, especially in existing construction, such as during a remodel.

One of the unique aspects of a ductless, mini-split install is in their wiring needs. While both most often require a dedicated circuit with a dedicated breaker in the electrical panel (some mini-splits can operate on 110v outlets), ductless mini-split systems additionally require wiring between the indoor and outdoor units, including power and control wiring, which is not typically the case for traditional, central air systems.

While insulated refrigerant lines used to connect indoor and outdoor units are available for both central and mini-split systems and cables combining power and control wiring are also available for mini-split systems, such as offered under the trademark “DUCKT-STRIP®,” no lineset combining low and high pressure refrigerant lines with the power and control cables needed for typical mini-split air-conditioning system installs is available, despite the two disciplines terminating at the same location at both ends. This forces installers, who are typically responsible for running both electrical cable and linesets, to undertake at least two separate utility runs. These runs typically involve at least one building envelope penetrations each, significantly increasing install time and cost as well as the potential for errors that could become pathways for moisture intrusion, increasing the risk of hidden water damage and eventual rot, relative to a single run.

Due to the differing systems and spacing between refrigerant and electrical connections, however, varying lengths must be able to be accounted for and it is also desirable to maintain adjustability should repairs be needed.

What is needed, therefore, is single lineset that provides all required conduits to connect an inside ductless, mini-split air-conditioning unit to an outside unit and that can be installed as a single run through a single building envelope penetration, while allowing the refrigerant and/or electrical wires/cables to slide, relative to an exterior insulation, allowing adjustment, repair, and even total replacement without disturbing an outside shell of the conduit.

SUMMARY

An integrated, insulated lineset particularly suitable for use in ductless, mini-split air conditioning systems is provided. The lineset combines high-and low-pressure refrigerant lines with the power and control wiring necessary to connect an outdoor condensing unit to an indoor evaporator unit. By consolidating these components into a single assembly, the lineset simplifies installation, reduces the number of required building envelope penetrations, and lowers the risk of moisture intrusion and subsequent structural damage such as rot.

In implementations, the integrated power and control wiring may be included embedded in the insulation, providing an additional layer of protection from the elements. In other implementations, the power and control wiring is laid between the lineset and insulation, in embodiments with about 2 feet of cable extending beyond each end of the lineset. In still other implementations, the lineset and power and control wiring are contained within a shell, with a low-pressure portion of the lineset separately insulated within the shell.

In implementations, the refrigerant lines and/or electrical wiring can slide longitudinally, relative to the surrounding insulation. This adjustability facilitates easier installation and service by accommodating variability in unit spacing and field conditions. The sliding functionality is enabled by a specialized insulation structure, which may be formed through extrusion and feature a cross section that minimizes contact with the lineset and power and control wiring while, in embodiments, simultaneously retaining air pockets that act as insulation. More specifically, an exemplary geometry creates longitudinal air pockets that enhance thermal insulation while minimizing friction and surface contact with the enclosed components.

In embodiments, material selection for the linesets, cables, and insulation further supports the low-friction sliding behavior.

The invention thereby provides an integrated, adjustable, and installer-friendly solution for the routing of all necessary mechanical and electrical connections in a mini-split HVAC installation.

The features and advantages described herein are not all-inclusive and, in particular, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims. Moreover, it should be noted that the language used in the specification has been selected principally for readability and instructional purposes and not to limit the scope of the inventive subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a typical ductless, mini-split HVAC system installation, showing an outdoor condensing unit connected to an indoor evaporator unit via a conventional, separate refrigerant and electrical service run;

FIG. 2 is a schematic illustration of a ductless, mini-split HVAC system installation using the disclosed integrated lineset, wherein the refrigerant lines and electrical wiring are enclosed within a common insulated assembly; and

FIG. 3 is a perspective view of an integrated lineset according to embodiments of the invention, showing outer insulation surrounding a bundle comprising two refrigerant lines, a power cable, and a control wire.

These and other features of the present embodiments will be understood better by reading the following detailed description, taken together with the figures herein described. The accompanying drawings are not intended to be drawn to scale. For purposes of clarity, not every component may be labeled in every drawing.

DETAILED DESCRIPTION

Referring now to FIG. 1, a conventional ductless, mini-split air-conditioning system installation is shown. An indoor unit (100), typically wall-mounted within a room, is connected to an outdoor unit (102) positioned outside of a conditioned building. In this conventional arrangement, two separate utility runs are required: one for the refrigerant lines (104) and another for the electrical wires (106). Each run typically penetrates the building envelope independently, increasing installation time and cost, while also presenting potential failure points for water ingress and hidden rot.

FIG. 2 illustrates an improved system configuration utilizing an integrated lineset (200) constructed in accordance with embodiments of the present disclosure. The integrated lineset (200) combines the electrical and refrigerant components into a single assembly, in embodiments insulated, thereby allowing a single building penetration to convey both refrigerant and electrical signals and power while reducing installation complexity and moisture intrusion risk.

FIG. 3 provides a perspective view of the integrated lineset (200). The lineset includes an outer shell (300), which encases a bundle of service components. These include at least one power cable (302), which may include one or more electrical conductors for supplying power to the indoor unit (100); at least one control wire (304), typically of smaller gauge, for signal or communication purposes; a low-pressure refrigerant line (306); and a high-pressure refrigerant line (310). The power cable(s) (302) and control wire(s) (304) may be fully jacketed, partially jacketed, or not jacketed, in various embodiments. In the depicted embodiment, the low-pressure refrigerant line (306) is separately wrapped in a layer of low-pressure refrigerant line insulation (308) to enhance thermal efficiency.

In embodiments, the outer shell is also made of a material having a relatively high thermal resistance.

The outer shell (300) may be formed through extrusion and optionally feature a structured internal geometry, such as a cellular cross section, to reduce contact area and allow the enclosed conduits to slide longitudinally relative to the insulation. This design facilitates in-field length adjustment of individual components during installation or repair, accommodates variable distances between the indoor and outdoor units, and can even allow for complete replacement of individual components without removal, using the outer shell (300) as a chase to pull a new conduit.

In embodiments, the electrical wiring (302, 304) is separated within its own dedicated channel within the outer shell (300), physically offset from the refrigerant lines (306, 310). In such embodiments, this separation improves thermal and electromagnetic isolation and further simplifies servicing. Material selection for the outer shell (300) may include low-friction polymeric foams or elastomeric blends to enable this sliding functionality without compromising insulating performance.

The described integrated lineset (200) addresses both logistical and functional challenges faced by HVAC installers. By consolidating the separate electrical and refrigerant runs into a single, adjustable unit, it reduces labor, shortens install time, and decreases the risk of improperly sealed penetrations that can lead to water damage and rot. Additionally, its modular design permits easier access for future maintenance and retrofit applications.

While various embodiments have been described above, those skilled in the art will recognize that modifications may be made without departing from the spirit and scope of the invention. For example, while the illustrated embodiment shows both power and signal wiring, some systems may only require one or the other, and such variations are contemplated. Similarly, while the refrigerant lines are depicted as copper tubes, the use of alternative refrigerant conduit materials is within the scope of the present disclosure.

Accordingly, it will be understood that the foregoing detailed description and accompanying figures are provided for purposes of illustration, and not limitation, and the invention is defined solely by the claims appended hereto.

The foregoing description of the embodiments of the present disclosure has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the present disclosure to the precise form disclosed. Many modifications and variations are possible in light of this disclosure. It is intended that the scope of the present disclosure be limited not by this detailed description, but rather by the claims appended hereto.

A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the scope of the disclosure. Although operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results.