CONDENSATE FLOW CONTROL IN PORTABLE AIR CONDITIONING UNITS

Abstract

A portable air conditioner unit includes a first heat exchanger, a second heat exchanger positioned below the first heat exchanger, and a spray pipe positioned between the first and second heat exchangers. The portable air conditioner unit also includes a valve that includes an inlet port, a first outlet port configured to direct fluid to a spray pipe, and a second outlet port configured to direct fluid to an exterior of the portable air conditioner unit. The portable air conditioner unit further includes a base pan defining a bottom reservoir within the portable air conditioner unit, a water level switch positioned in the base pan, and a pump positioned in the base pan. The pump is connected to the inlet port of the valve. The pump is operable to flow fluid from the base pan to the inlet port of the valve.

Claims

1. A method of operating a portable air conditioner unit, the portable air conditioner unit comprising a first heat exchanger, a second heat exchanger, a controller, and a valve defining a first outlet port and a second outlet port, the first heat exchanger positioned above the second heat exchanger, the method comprising: determining, by the controller, a mode of operation; checking, by the controller, a water level switch to determine a water level indicated by the water level switch; activating, by the controller, a pump based on the water level indicated by the water level switch; and switching, by the controller, to one of the first outlet port and the second outlet port based on the mode of operation and the water level indicated by the water level switch, wherein the first outlet port of the valve directs fluid to a spray pipe positioned above the second heat exchanger, and wherein the second outlet port of the valve directs fluid to an exterior of the portable air conditioner unit.

2. The method of claim 1, wherein the water level switch is disposed in a base pan of the portable air conditioning unit.

3. The method of claim 1, further comprising deactivating the pump based on the water level indicated by the water level switch being beneath a predetermined low level.

4. The method of claim 1, wherein the spray pipe comprises a plurality of holes configured to spray fluid onto the second heat exchanger.

5. The method of claim 1, wherein determining the mode of operation comprises determining that the portable air conditioner unit is operating in one of a heating mode and a cooling mode.

6. The method of claim 5, wherein determining the mode of operation comprises determining that the portable air conditioner unit is operating in the cooling mode, wherein the water level indicated by the water level switch is above a predetermined low level and below a predetermined high level, and wherein switching to one of the first outlet port and the second outlet port comprises switching to the first outlet port based on the cooling mode and the water level between the predetermined low level and the predetermined high level.

7. The method of claim 5, wherein determining the mode of operation comprises determining that the portable air conditioner unit is operating in the heating mode, wherein the water level indicated by the water level switch is above a predetermined low level, and wherein switching to one of the first outlet port and the second outlet port comprises switching to the second outlet port based on the heating mode and the water level above the predetermined low level.

8. The method of claim 5, wherein determining the mode of operation comprises determining that the portable air conditioner unit is operating in the cooling mode, wherein the water level indicated by the water level switch is above a predetermined high level, and wherein switching to one of the first outlet port and the second outlet port comprises switching to the second outlet port based on the cooling mode and the water level above the predetermined high level.

9. A portable air conditioner unit comprising: a first heat exchanger; a second heat exchanger, the first heat exchanger positioned above the second heat exchanger; a valve defining a first outlet port and a second outlet port; and a controller, the controller configured to: determine a mode of operation; check a water level switch to determine a water level indicated by the water level switch; activate a pump based on the water level indicated by the water level switch; and switch to one of the first outlet port and the second outlet port based on the mode of operation and the water level indicated by the water level switch, wherein the first outlet port of the valve directs fluid to a spray pipe positioned above the second heat exchangers, and wherein the second outlet port of the valve directs fluid to an exterior of the portable air conditioner unit.

10. The portable air conditioner unit of claim 9, wherein the water level switch is disposed in a base pan of the portable air conditioning unit.

11. The portable air conditioner unit of claim 9, wherein the controller is further configured to deactivate the pump based on the water level indicated by the water level switch being beneath a predetermined low level.

12. The portable air conditioner unit of claim 9, wherein the spray pipe comprises a plurality of holes configured to spray fluid onto the second heat exchanger.

13. The portable air conditioner unit of claim 9, wherein determining the mode of operation comprises determining that the portable air conditioner unit is operating in one of a heating mode and a cooling mode.

14. The portable air conditioner unit of claim 13, wherein determining the mode of operation comprises determining that the portable air conditioner unit is operating in the cooling mode, wherein the water level indicated by the water level switch is above a predetermined low level and below a predetermined high level, and wherein switching to one of the first outlet port and the second outlet port comprises switching to the first outlet port based on the cooling mode and the water level between the predetermined low level and the predetermined high level.

15. The portable air conditioner unit of claim 13, wherein determining the mode of operation comprises determining that the portable air conditioner unit is operating in the heating mode, wherein the water level indicated by the water level switch is above a predetermined low level, and wherein switching to one of the first outlet port and the second outlet port comprises switching to the second outlet port based on the heating mode and the water level above the predetermined low level.

16. The portable air conditioner unit of claim 13, wherein determining the mode of operation comprises determining that the portable air conditioner unit is operating in the cooling mode, wherein the water level indicated by the water level switch is above a predetermined high level, and wherein switching to one of the first outlet port and the second outlet port comprises switching to the second outlet port based on the cooling mode and the water level above the predetermined high level.

17. A portable air conditioner unit comprising: a first heat exchanger; a second heat exchanger positioned below the first heat exchanger; a spray pipe positioned above the second heat exchangers, the spray pipe comprising a plurality of holes configured to spray fluid onto the second heat exchanger; a valve comprising an inlet port, a first outlet port configured to direct fluid to the spray pipe, and a second outlet port configured to direct fluid to an exterior of the portable air conditioner unit; a base pan defining a bottom reservoir within the portable air conditioner unit; a water level switch positioned in the base pan, a controller; and a pump positioned in the base pan, the pump connected to the inlet port of the valve, whereby the pump is operable to flow fluid from the base pan to the inlet port of the valve, wherein, the controller is configured to: determine a mode of operation; check the water level switch to determine a water level indicated by the water level switch; activate the pump based on the water level indicated by the water level switch; and switch to one of the first outlet port and the second outlet port based on the mode of operation and the water level indicated by the water level switch.

18. The portable air conditioner unit of claim 17, wherein the first heat exchanger is mounted to the second heat exchanger by a bracket, whereby the first heat exchanger is approximately perpendicular, or at any angle, to the second heat exchanger, the second heat exchanger adjacent the base pan.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

[0011] FIG. 1 provides a perspective view of an example embodiment of a portable air conditioner unit in accordance with aspects of the present disclosure.

[0012] FIG. 2 provides a rear perspective view of the example portable air conditioner unit of FIG. 1 in accordance with aspects of the present disclosure.

[0013] FIG. 3 provides a top perspective view of an example base pan of the example portable air conditioner unit of FIG. 1 in accordance with aspects of the present disclosure.

[0014] FIG. 4 provides a side view of an example spray pipe according to aspects of the present disclosure.

[0015] FIG. 5 provides a schematic diagram of an example cooling mode of the example portable air conditioner unit of FIG. 1 in accordance with aspects of the present disclosure.

[0016] FIG. 6 provides a schematic diagram of an example heating mode of the example portable air conditioner unit of FIG. 1 in accordance with aspects of the present disclosure.

[0017] FIG. 7 provides a flow diagram of an example method of operating the portable air conditioner unit in accordance with aspects of the present disclosure.

[0018] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0019] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0020] As used herein, the terms includes and including are intended to be inclusive in a manner similar to the term comprising. Similarly, the term or is generally intended to be inclusive (i.e., A or B is intended to mean A or B or both). Approximating language, as used herein throughout the specification and claims, is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as about, approximately, and substantially, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. For example, the approximating language may refer to being within a ten percent (10%) margin.

[0021] FIG. 1 provides a perspective view of a portable air conditioner unit (PAC) 100 according to an example embodiment of the present subject matter. It will be understood that PAC 100 is provided by way of example only and that the present subject matter may be used in or with any suitable portable air conditioner unit in alternative example embodiments. Moreover, with reference to each of FIGS. 1 and 2, PAC 100 may define a vertical direction V, a lateral direction L, and a transverse direction T, which are mutually perpendicular and form an orthogonal direction system. It should be understood that these directions are presented for example purposes only, and that relative positions and locations of certain aspects of PAC 100 may vary according to specific embodiments, spatial placement, or the like.

[0022] In general, as seen in FIG. 1, PAC 100 may include a case 101 for enclosing the components of PAC 100. Case 101 may generally define the overall appearance of PAC 100, e.g., case 101 may be smooth or decorative to make PAC 100 visually appealing to a user. Generally, PAC 100 is operable to generate chilled and/or heated air in order to regulate the temperature of an associated room or structure. In other words, PAC 100 may include operating in one of a heating mode and a cooling mode, as will be described below. As discussed in greater detail below, a sealed system 150 of PAC 100 is disposed within the casing 101. In some example embodiments, extending from case 101 may be a vent hose 102. In general, vent hose 102 may direct exhaust air from PAC 100 to the external environment. For example, an end 103 of vent hose 102 may be positioned in a window of a structure to vent treated air outside of the structure. Moreover, an outlet 105 of PAC 100 may generally direct treated air to the conditioned space. For example, exhaust air may be directed to flow through vent hose 102 and treated air flowing through PAC 100 may be directed through outlet 105.

[0023] In general, sealed system 150 may include a compressor 152 (FIGS. 5 and 6) and heat exchangers. As may be seen in FIG. 2, sealed system 150 within case 101 may include a first heat exchanger 104 and a second heat exchanger 106. In general, first heat exchanger 104 may be generally configured to treat air around PAC 100 and provide the treated air to the conditioned space, and second heat exchanger 106 may be configured to exhaust treated air to the exterior, e.g., to vent treated air outside of the structure. Furthermore, first heat exchanger 104 may be mounted to second heat exchanger 106 by a bracket 108. In some example embodiments, first heat exchanger 104 may be approximately perpendicular, or nay other suitable angle, to second heat exchanger 106. As shown, second heat exchanger 106 may be adjacent a base pan 112, e.g., second heat exchanger 106 may be mounted within or on base pan 112. In general, base pan 112 may define a bottom reservoir 113 within the PAC 100. Generally, condensate from the operation of PAC 100 will drip into bottom reservoir 113, where the condensate may be repurposed or removed from the system, as will be explained below.

[0024] Referring now generally to FIGS. 2-6, mounted within base pan 112 may be a pump 114 and a water level switch 116. In general, the operation of pump 114 may be based on a water level indicated by water level switch 116. For example, pump 114 may be deactivated based on the water level indicated by water level switch 116 being beneath a predetermined low level 142 (FIG. 5), e.g., the predetermined low level 142 is generally illustrated in FIG. 5 as the lowest vertical depth of condensate in bottom reservoir 113. In another example, pump 114 may be activated when the water level indicated by water level switch 116 is above a predetermined high level 144 (FIG. 5), e.g., the predetermined high level 144 is generally illustrated in FIG. 5 as the highest vertical depth of condensate in bottom reservoir 113. Furthermore, pump 114 may be in fluid connection with a valve 120 generally configured to direct fluid to one of two outlet ports. For example, pump 114 may be in fluid connection with inlet port 122 of valve 120, which may direct fluid to either first outlet port 124 or second outlet port 126. In general, first outlet port 124 may direct fluid to a spray pipe 118, and second outlet port 126 may direct fluid to an exterior of PAC 100, e.g., second outlet port 126 may direct fluid to a drain or other suitable exterior location. In general, spray pipe 118 may be positioned above second heat exchanger 106, below first heat exchanger 104, or between the first and second heat exchangers 104, 106. As particularly seen in FIG. 4, the spray pipe may generally include a plurality of holes 119 configured to spray fluid onto the second heat exchanger 106.

[0025] In general, when PAC 100 operates in the cooling mode, first heat exchanger 104 operates as an evaporator such that condensate condensed from first heat exchanger 104 drops through second heat exchanger 106, which operates as the condenser, then drips and collects in the bottom reservoir 113. Additionally, when PAC 100 operates in the heating mode, condensate condensed from second heat exchanger 106 which operates as the evaporator, may drop into bottom reservoir 113.

[0026] PAC 100 further includes a controller 132 with user inputs, such as buttons, switches and/or dials. Controller 132 regulates operation of PAC 100. Thus, controller 132 is in operative communication with various components of PAC 100, such as components of sealed system 150 and/or a temperature sensor, such as a thermistor or thermocouple, for measuring the temperature of the interior atmosphere. In particular, controller 132 may selectively activate sealed system 150 in order to chill or heat air around sealed system 150, e.g., in response to temperature measurements from the temperature sensor.

[0027] Controller 132 includes memory and one or more processing devices such as microprocessors, CPUs or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of PAC 100. The memory can represent random access memory such as DRAM, or read only memory such as ROM or FLASH. The processor executes programming instructions stored in the memory. The memory can be a separate component from the processor or can be included onboard within the processor. Alternatively, controller 132 may be constructed without using a microprocessor, e.g., using a combination of discrete analog and/or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software.

[0028] As may be seen in FIGS. 5 and 6, sealed system 150 is shown operating in a cooling mode in FIG. 5, and is shown operating in a heating mode in FIG. 6. As illustrated, sealed system 150 includes a compressor 152, first heat exchanger 104, and second heat exchanger 106. As is generally understood, various segments of any suitable tubing, piping, or conduit may be utilized to flow refrigerant between the various components of sealed system 150. Thus, for example, first heat exchanger 104, and second heat exchanger 106 may be in fluid communication with each other and compressor 152 via suitable conduit 158. The unlabeled arrows in FIGS. 5 and 6 generally indicate the direction of refrigerant flow within adjacent conduits 158 of sealed system 150.

[0029] As shown in FIG. 5, during operation of sealed system 150 in the cooling mode, compressor 152 operates to increase a pressure of the refrigerant within compressor 152. In particular, vapor refrigerant from first heat exchanger 104 is directed to compressor 152 while in the cooling mode. Vapor refrigerant from first heat exchanger 104 may be a fluid in the form of a superheated vapor. Upon exiting first heat exchanger 104, the refrigerant may enter compressor 152, and compressor 152 may operate to compress the refrigerant. Accordingly, the pressure and temperature of the refrigerant may be increased in compressor 152 such that the refrigerant becomes a more high-pressure superheated vapor.

[0030] When sealed system 150 is operating in the cooling mode, second heat exchanger 106 is disposed downstream of compressor 152, and second heat exchanger 106 acts as a condenser. Thus, second heat exchanger 106 is operable to reject heat into the exterior atmosphere, e.g., through vent hose 102 of casing 101, when sealed system 150 is operating in the cooling mode. For example, the superheated vapor from compressor 152 may enter second heat exchanger 106 via suitable conduit or piping 158 that extends between and fluidly connects compressor 152 and second heat exchanger 106. Within second heat exchanger 106, the refrigerant from compressor 152 transfers energy to the exterior atmosphere and condenses into a saturated liquid, a liquid-vapor mixture, and/or a subcooled liquid. An air handler or fan 107 may be positioned adjacent second heat exchanger 106 to facilitate or urge a flow of air across second heat exchanger 106 in order to facilitate heat transfer.

[0031] An expansion device 160 is disposed on conduit 158 between second heat exchanger 106 and first heat exchanger 104. In the cooling mode, liquid refrigerant from second heat exchanger 106 travels through expansion device 160 before flowing through first heat exchanger 104. Expansion device 160 may generally expand the refrigerant, thereby lowering its pressure and temperature. The refrigerant may then be flowed through first heat exchanger 104.

[0032] As used herein, expansion device may refer to any device suitable for throttling or expanding the refrigerant flowing through a conduit. For example, according to the illustrated embodiment, expansion device 160 is a capillary tube that allows refrigerant to expand after leaving second heat exchanger 106 prior to entering first heat exchanger 104. Other types, configurations, and locations of expansion devices are possible and within the scope of the present subject matter.

[0033] First heat exchanger 104 is disposed on conduit 158 between expansion device 160 and compressor 152. In this manner, when sealed system 150 is operating in the cooling mode, first heat exchanger 104 is disposed downstream of expansion device 160 and acts as an evaporator. Thus, first heat exchanger 104 is operable to heat refrigerant within first heat exchanger 104 when sealed system 150 is operating in the cooling mode. For example, within first heat exchanger 104, the refrigerant from expansion device 160 receives energy and vaporizes into superheated vapor and/or high quality vapor mixture. An air handler or fan 105 may be positioned adjacent first heat exchanger 104 to facilitate or urge a flow of air across first heat exchanger 104 in order to facilitate heat transfer.

[0034] As may be shown in FIG. 6, during operation of sealed system 150 in the heating mode, a valve 110 reverses the direction of refrigerant flow through sealed system 150. Thus, in the heating mode, first heat exchanger 104 is disposed downstream of compressor 152 and acts as a condenser, e.g., such that first heat exchanger 104 is operable to reject heat into the room in which PAC 100 is located. The refrigerant from first heat exchanger 104 travels through expansion device 160, which may generally expand the refrigerant, thereby lowering its pressure and temperature, as described above. The refrigerant may then flow through second heat exchanger 106.

[0035] Second heat exchanger 106 is disposed on conduit 158 between expansion device 160 and compressor 152. In this manner, when sealed system 150 is operating in the heating mode, second heat exchanger 106 is disposed downstream of expansion device 160 and acts as an evaporator. Thus, second heat exchanger 106 is operable to heat refrigerant within second heat exchanger 106 when sealed system 150 is operating in the heating mode. For example, within second heat exchanger 106, the refrigerant from expansion device 160 receives energy and vaporizes into superheated vapor and/or high quality vapor mixture. From second heat exchanger 106, refrigerant is directed back to compressor 152, and the heat pump cycle may be repeated.

[0036] In general, controller 132 may be generally configured to determine a mode of operation, check water level switch 116 to determine the water level and activate pump 114 based on the water level indicated by water level switch 116. For example, determining the mode of operation includes determining that PAC 100 is operating in one of the heating mode and the cooling mode. Controller 132 may also be configured to switch to one of the first outlet port 124 and the second outlet port 126 based on the determined mode of operation and the water level indicated by water level switch 116. The switching of outlet port of valve 120 will be described in further detail herein.

[0037] For example, as illustrated in of FIG. 5, when controller 132 determines the mode of operation is the cooling mode, and the water level indicated by water level switch 116 is above the predetermined low level 142 and below the predetermined high level 144, switching to one of the first outlet port 124 and the second outlet port 126 includes switching to the first outlet port 124 based on being in the cooling mode and the water level being between the predetermined low level 142 and the predetermined high level 144. As such, the fluid is directed to spray pipe 118 where fluid is repurposed and sprayed down onto second heat exchanger 106.

[0038] In another example, as illustrated in of FIG. 6, when controller 132 determines the mode of operation is the heating mode, and the water level indicated by water level switch 116 is above the predetermined low level 142, switching to one of the first outlet port 124 and the second outlet port 126 includes switching to the second outlet port 126 based on being in the heating mode and the water level being above the predetermined low level 142.

[0039] Furthermore, in an additional example, when controller 132 determines the mode of operation is the cooling mode, wherein the water level indicated by water level switch 116 is above a predetermined high level 144, switching to one of the first outlet port 124 and the second outlet port 126 includes switching to the second outlet port 126 based on being in the cooling mode and the water level being above the predetermined high level 144.

[0040] Referring now to FIG. 7, a flow diagram of an example embodiment of a method 700 of operating a PAC is illustrated in accordance with aspects of the present subject matter. In general, method 700 will be described herein with reference to the embodiments of PAC 100 described above with reference to FIGS. 1-6. However, it should be appreciated by those of ordinary skill in the art that the disclosed method 700 may generally be utilized in association with apparatuses and systems having any other suitable configuration. In addition, although FIG. 7 depicts steps performed in a particular order for purposes of illustration and discussion, the methods discussed herein are not limited to any particular order or arrangement. One skilled in the art, using the disclosures provided herein, will appreciate that various steps of the methods disclosed herein can be omitted, rearranged, combined, and/or adapted in various ways without deviating from the scope of the present disclosure.

[0041] As shown in FIG. 7, at (710), method 700 may generally include determining a mode of operation. Determining the mode of operation includes determining that the PAC is operating in one of the heating mode and the cooling mode. At (720), method 700 may generally include checking a water level switch, such as water level switch 116, to determine a water level indicated by the water level switch. At (730), method 700 may generally include activating a pump, such as pump 114, based on the water level indicated by the water level switch. At (740), method 700 may generally include switching to one of a first outlet port, such as first outlet port 124, and a second outlet port, such as second outlet port 126, based on the determined mode of operation and the water level indicated by the water level switch. In some example embodiments, method 700 may further include, at (750), deactivating the pump based on the water level indicated by the water level switch being beneath a predetermined low level, such as predetermined low level 142.

[0042] As may be seen from the above, a PAC unit includes a valve that is switches outlet ports when the water level reaches a predetermined high level in order to rapidly reduce the amount of condensate within the PAC. Particularly, this switch may advantageously occur while the PAC is operating. Additionally, the PAC unit operating in the heating mode may advantageously switch outlet ports to reduce the amount of condensate within the PAC, in order to keep the water level at a predetermined low level. Overall, the switching of the outlet ports may advantageously reduce leakage and or flooding from the PAC.

[0043] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.