SENSOR DEVICE AND CONDENSATE WATER REMOVAL DEVICE WITH A SENSOR DEVICE

Abstract

A sensor device for detection of water, having an inlet connector with an inlet opening, and at least one sensor element, wherein the inlet connector is exposed to or connected to a source of water, the inlet opening forms at least a part of a reservoir for reception of the water from the source of water, the reservoir is in fluid communication with a vent that vents the reservoir to the surrounding air and the sensor element is positioned within or adjacent to the inlet opening and/or the reservoir, such that it protrudes into the reservoir or forms an interface of the reservoir.

Claims

1. A sensor to detect water, the sensor comprising: an inlet connector with an inlet opening, the inlet connector being connectable to a source of water, the inlet opening forming at least a part of a reservoir for reception of water from the source of water; at least one sensor element positioned within or adjacent to the inlet opening and/or the reservoir, such that the sensor element protrudes into the reservoir or forms an interface of the reservoir; and a vent in fluid communication with the reservoir, the vent venting the reservoir to the surrounding air.

2. The sensor according to claim 1, further comprising at least two sensor elements or three sensor elements, and wherein the sensor elements are positioned at different measuring positions along a measuring axis.

3. The sensor according to claim 1, wherein the reservoir is further formed at least in part by a first condensate water hose, that connects the inlet connector to a source of condensate water.

4. The sensor according to claim 3, wherein the first condensate water hose comprises a corrugated hose section or an extensible corrugated hose section.

5. The sensor according to claim 3, wherein the condensate water hose comprises: a proximal end section adapted to connect to the inlet connector; and a distal end section adapted to connect to a source of condensate water, wherein the distal end section comprises at least two connector sections with different opening widths that adjoin each other, and wherein the connector sections are removably attached to the condensate water hose and/or each other.

6. The sensor according to claim 1, wherein the inlet connector is arranged on a first housing of a condensate water remover, wherein the reservoir is further formed at least in part by an internal chamber of the first housing and the internal chamber is arranged adjacent to and in fluid communication with the inlet opening of the inlet connector.

7. The sensor according to claim 1, wherein each sensor element is adapted to generate an electric sensor signal, wherein the electric sensor signal is indicative of at least one of: a presence or absence of water at a sensing surface of the sensor element, a pressure of a fluid in contact with the sensor element, a temperature of a fluid in contact with the sensor element, a thermal capacity of a fluid in contact with the sensor element, or a conductivity of a fluid in contact with the sensor elements.

8. The sensor according to claim 1, wherein at least one sensor element is an optical sensor, wherein the sensor further comprises a transparent sensor body, which is arranged adjacent to the reservoir and further comprises a prism-shaped or conical-shaped reflection face, which is facing towards the reservoir and is in contact with it, wherein the at least one optical sensor comprises a set of one light emitter and one corresponding light receiver, which are arranged adjacent to or integrated into a back surface of the sensor body, which is essentially opposite to the reflection face, wherein the light of the light emitter is directed towards the reflection face and the light receiver provides an electronic sensor signal that is indicative of an amount of light internally reflected back from the reflection face and received by the light receiver, and wherein an electronics unit is connected to the sensor element and is adapted to determine whether water is present or absent at the reflection face, based on the electronic sensor signal of the light receiver.

9. The sensor according to claim 8, further comprising at least two optical sensors, wherein each of the at least two optical sensors comprises a set of one light emitter and one corresponding light receiver, wherein the one sensor body has an elongate shape and extends along or in parallel to the measuring axis, wherein each set of light emitters and light receivers is arranged adjacent to or integrated into a back surface of the one sensor body, which is essentially opposite to the reflection face, facing away from the reservoir, wherein the sets are positioned at different measuring positions along the measuring axis, wherein the light of the light emitters is directed towards the reflection face and the light receivers provide electronic sensor signals that are indicative of an amount of light internally reflected back from the reflection face and received by the light receivers, and wherein the electronics unit is connected to the sensor elements and is adapted to determine whether water is present or absent at each measuring position at the reflection face, based on the electronic sensor signals of the light receivers.

10. The sensor according to claim 8, further comprising a shield that is arranged between the light emitter and the light receiver of at least one optical sensor or between the light emitters and light receivers of different optical sensors.

11. The sensor according to claim 1, further comprising an UV-light emitter that is adapted to emit ultra violet light onto the at least one sensor element.

12. The sensor according to claim 11, wherein an electronics unit controls the UV-light emitter to emit light onto the at least sensor element periodically, and/or wherein the electronics unit is connected to the UV-light emitter and to the at least one sensor element and is adapted to control the UV-light emitter to emit light onto the at least one sensor element only when the presence of water in the reservoir is detected based on a signal of the at least one sensor element.

13. A condensate water remover to remove water from an HVACR system, the condensate water remover comprising: a sensor according to claim 1; at least a first housing; a pump; an outlet connector with an outlet hole; and an electronics unit, wherein the inlet connector of the sensor is arranged on the first housing, wherein the pump is adapted to pump water out of the reservoir of the sensor via a fluid channel system that is connected to an outlet port of the reservoir and towards the outlet connector, and wherein the electronics unit is electronically connected to the sensor element and adapted to determine a presence or absence of water and/or a level of water within the reservoir and to provide a control signal, based on the detected presence and/or level of condensate water, to the pump.

14. The condensate water remover according to claim 13, wherein the first housing has a rectangular or square cross-section, wherein the measuring axis of the sensor extends along a diagonal line of the cross-section, and wherein the outlet opening of the reservoir is positioned at one of the ends of the diagonal line.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0050] The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitive of the present invention, and wherein:

[0051] FIG. 1 schematically shows a sectional view of a sensor device,

[0052] FIG. 2 schematically shows a sectional view of a sensor device,

[0053] FIG. 3 schematically shows a sectional view of a sensor device,

[0054] FIG. 4 schematically shows a sectional view of a reservoir,

[0055] FIG. 5.1 schematically shows an optical sensor adjacent to an empty reservoir,

[0056] FIG. 5.2 schematically shows an optical sensor adjacent to a reservoir filled with water,

[0057] FIG. 6 schematically shows an optical sensor in a perspective view,

[0058] FIG. 7 schematically shows a condensate water removal device,

[0059] FIG. 8 schematically shows a condensate water removal device,

[0060] FIG. 9 schematically shows a sectional view of a sensor device,

[0061] FIG. 10 schematically shows a sectional view of a cut out of a sensor device,

[0062] FIG. 11 schematically shows an optical sensor in a perspective view, and

[0063] FIG. 12 schematically shows a sectional view of an optical sensor adjacent to a reservoir filled with water.

DETAILED DESCRIPTION

[0064] FIGS. 1, 2 and 3 show sectional views of examples of a sensor device 100 of the present invention. In each one of these figures, an inlet connector 110 with an inlet opening 111 at its distal end is connected to a first housing 310 of, e.g., a condensate water removal device 300. From the inlet opening 111 a bore extends further inside the inlet connector 110, forming a reservoir 130, to receive water from a source of water. A sensor element 120 is arranged adjacent to or within the reservoir 130 to sense the presence and/or amount of water inside the reservoir 130. Possible electrical connections to other elements like, e.g., to an electronics unit. The inlet connector 110 further comprises a vent 131 close to or at a top side of the sensor device 100 to prevent a siphon effect. Close to or at a deepest point of the reservoir 130, the sensor device 100 comprises an outlet port 132 through which the reservoir 130 is in fluid communication with a fluid channel system 360, e.g., of the condensate water removal device 300.

[0065] The inlet connector 110 of FIG. 1 is of cylindrical shape and small enough in diameter, so that condensate water hoses, which are typically used to connect a drain port of a drip tray of a HVACR-system to a condensate water removal device 300 or a drain, can be plugged onto the inlet connector 110 easily. For improved tightness, the inlet connector 110 may be in the shape of a ribbed hose nozzle.

[0066] Further to FIG. 1, FIG. 2 shows a shorter inlet connector 110 with a wider diameter, to make room for a wider reservoir 130. A first condensate water hose 200 is shown connected to the inlet connector 110 and comprises a widened connection section 220, that fits to the inlet connector 110 and forms a part of the wider reservoir 130. Adjacent to that widened connection section 220 the hose 200 comprises a corrugated hose section 210, which allows for very flexible adaption to different installation geometries.

[0067] FIG. 3 shows an inlet connector 110 that is similar to that of FIG. 1. However, in this example, the bore through the inlet connector 110, which extends from the inlet opening 111, meets with an internal chamber 311 of the first housing 310. The inlet opening 111 and the internal chamber 311 together form the reservoir 130. Vent 131 and outlet port 132 are arranged at that internal chamber 311.

[0068] FIG. 4 shows a sectional view through sectional plane A, as indicated in FIG. 3. The first housing 310 has a rectangular shape and the sensor element 120 is aligned along a measuring axis 126 that extends on a diagonal of the rectangular housing 310. The outlet port 132 is positioned in the lower right corner, while the vent 131 is positioned at the top left corner. In that arrangement, the first housing 310 may be installed in two different orientations: Either with the bottom side or the right side (in the perspective of this figure) on the ground, as indicated with arrows. In these two orientations, the vent 131 will be at the highest point of the reservoir 130 and can provide for an effective prevention of a siphon effect, without spilling water. At the same time, the outlet port 132 is always arranged at the lowest level of the reservoir 130. Therefore, the water can effectively be withdrawn from the reservoir 130, e.g., when the outlet port 132 is connected to a pump unit. The sensor device 100 may comprise multiple sensor elements 120′, 120″, 120′″ which are aligned at different positions along the measuring axis 126.

[0069] FIGS. 5.1 and 5.2 show a section of a sensor device 100 with an optical sensor element 120. The sensor element 120 is arranged at and/or held by a wall section of the inlet connector 110 or first housing 310. It comprises a sensor body 121 with a prism shaped cross section. At a back surface 123 of the sensor body 121 a light emitter 124, a light receiver 125 and a shield 127 are arranged. The shield 127 protrudes into the sensor body 121 to effectively shield the light receiver 125 from stray light. A substrate 128, e.g. a PCB, is arranged to hold the shown components.

[0070] In FIG. 5.1 the reservoir 130 is empty (or at least there is no water in close proximity to the sensor element 120). Light from the light emitter 124, as indicated by arrows, is directed towards a first reflection face 122. The material of the sensor body 121 (i.e. its refractive index) and the angle of incidence of the light is chosen such that total internal reflection occurs at the internal side of the reflection face 122, when there is no water in contact with the outer side of the reflection face 122. The light is reflected towards a second reflection face 122, where another total internal reflection occurs, such that essentially all light from the light emitter 124 is eventually directed towards the light receiver 125.

[0071] In FIG. 5.2 the reservoir 130 is filled with water (or at least a section of the reservoir 130 in close proximity to the sensor element 120). The Material (i.e. its refractive index) and the angle of incidence are chosen such that the condition for total internal refraction is not met, when the outer side of the reflection face 122 is in contact with water. Substantial amounts of light will be refracted out of the sensor body 121, at both reflection faces 122. Eventually, a much lower amount of light reaches the light receiver 125, as schematically indicated by the thin line of the arrow after the first reflection and the dotted line of the arrow after the second reflection.

[0072] FIG. 6 shows a sensor element 120, which is an optical sensor with two sensor elements 120′, 120″ in a perspective view. Each sensor element 120′, 120″ comprises a set of a light emitter 124′, 124″ and a light receiver 125′, 125″. The two sets of light emitters 124′, 124″ and light receivers 125′, 125″ are arranged at different longitudinal positions on a back surface of a joint sensor body 121. A cross-shaped shield 127 shields the light receivers 125′, 125″ from stray light of the corresponding light emitter 124′, 124″ of the same set as well as from stray light of the light emitter 124′, 124″ of the respective other set. A substrate 128 is arranged to hold the shown components, i.e., the light emitters 124′, 124″, light receivers 125′, 125″ and the shield 127.

[0073] FIGS. 7 and 8 show examples of condensate water removal devices 300, each comprising an example of the sensor device 100. In both figures, the inlet connector 110 of the sensor device 100 is connected to a first housing 310 of the condensate water removal device 300. An inlet opening 111 and an internal chamber 311 of the housing 310 together form a reservoir 130 to receive water. A sensor element 120 is arranged adjacent to the reservoir 130. Furthermore, a vent 131 is arranged at the internal chamber 311. An outlet port 132 connects the reservoir 130 to a fluid channel system 360. The condensate water removal device 300 further comprises a pump unit 330, an electronics unit 350 and an outlet connector 340 with an outlet hole 341. The inlet connector 110 is plugged into a first hose through which water is received from a source of water, e.g. a drain port of a drip tray. The outlet connector 340 is also connected to another hose, through which water can be pumped towards a drain.

[0074] FIG. 7 shows a setup than comprises only one housing 310 with sensor device 100, electronics unit 350 and pump unit 330 attached or integrated to it. The electronics unit 350 is adapted to evaluate the sensor signal of the sensor element 120 to determine a presence and/or a level of water present in the reservoir 130 and control the pump unit 330 to withdraw that water by way of the fluid channel system 360.

[0075] Further to that, FIG. 8 shows a setup with a first housing 310 and a second housing 320, which may be referred to as a split-pump design. The first housing 310 comprises the sensor device 100 and the electronics unit 350, the second housing 320 comprises the pump unit 360 (and possible further electronics units). The fluid channel system 360 comprises a section that is formed by an intermediate hose 370. An electronic communication cable 380 is connected to both devices and provides for data and/or power transmission between the electronics units 350.

[0076] FIG. 9 schematically shows a sectional view of an example of a sensor device 100 of the present invention, wherein the sensor device 100 comprises an inlet opening 111 at its distal end, which is connected to a first housing 310 of, e.g., a condensate water removal device 300.

[0077] Further to the example shown in FIG. 1, the outlet port 132 is arranged at an end surface 134 of an L-shaped intake pipe 133. The end surface is tilted by an angle α=30° with respect to a horizontal plane.

[0078] In an example of the sensor device 100, the intake pipe 133 is arranged rotatably in a socket on an inner wall of the reservoir 130. Thus, the intake pipe 133 can be adapted to different orientations of the sensor device 100.

[0079] FIG. 10 schematically shows a sectional view of a sensor device 100, wherein the sensor device 100 comprises an inlet opening 111 at its distal end, which is connected to a first housing 310 of, e.g., a condensate water removal device 300.

[0080] Further to the example shown in FIG. 2, the sensor device 100 comprises a first condensate water hose 200 comprising a filtering device 230. For example, the filtering device 230 comprises a small sponge 231, which is pushed into the hose 200 near a distal end 250 of the hose 200.

[0081] The condensate water hose 200 comprises a proximal end section 240 adapted to connect to the inlet connector 110 and a distal end section 250 adapted to connect to a source of condensate water. The distal end 250 section comprises at least two connector end sections 251, 251′, 251″ with different opening widths, that adjoin each other. The end sections 251, 251′, 251″ are removably attached to the condensate water hose 200 and/or each other. For example, the hose 200 is made of rubber and the opening widths of the connector end sections 251, 251′, 251″ get smaller starting from the distal end 250. Thus, it is possible, that a user simply cuts off the sections that are too wide for a tight connection to a given source of water, for example with a carpet cutter.

[0082] FIG. 11 schematically shows a sensor element 120, which is an optical sensor 120, in a perspective view.

[0083] Further to the example shown in FIG. 6, the optical sensor 120 further comprises an UV-light emitter 129, which is arranged on the substrate 128 with the light emitters 124′, 124″, light receivers 125′, 125″ and the shield 127.

[0084] The UV-light emitter 129 is adapted to emit ultra violet light onto the sensor elements 120′, 120″. With the UV-light emitter 129 directed onto the sensor elements 120′, 120″ the sensor elements 120′, 120″ are kept free of mould and/or algae.

[0085] The electronics unit 350 can control the UV-light emitter 129 to emit light onto the sensor elements 120′, 120″ periodically. The electronics unit 350 may be connected to the UV-light emitter 129 and to the sensor elements 120′, 120″ and may be adapted to control the UV-light emitter 129 to emit light onto the sensor elements 120′, 120″ only when the presence of water in the reservoir 130 is detected based on a signal of the sensor elements 120′, 120″.

[0086] The UV-light emitter 129 is arranged directly next to the light emitters 124′, 124″ and light receivers 125′, 125″ of the optical sensor on the same substrate 128. Thus, the transparent sensor body 121 can be illuminated from behind.

[0087] In this case, however, it could be that without water on the reflection face 122 the UV-light is also totally internally reflected. Thus, the sterilizing effect would be nil. Further, the emission of UV light only when there is water ensures that even with the described optical sensors the UV light really hits the surfaces that come into contact with water or penetrates it and that the water itself and other surfaces within the reservoir 130 can also be irradiated. This is shown in FIG. 12, which schematically shows a sensor element 120, which is an optical sensor, adjacent to a reservoir 130 filled with water.

[0088] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.