Condensate Transfer Systems for Self-Contained Heat Pump Room Conditioning Units

FIELD

The present disclosure relates generally to room conditioning (e.g., heating and cooling) units and more particularly to systems and methods for removal of condensate from self-contained heat pump room conditioning units, such as saddle window heat pump conditioning units or the like.

BACKGROUND

Self-contained room conditioning units can be employed to heat a specific room or other area within a building. Typically, such units are positioned in an opening of a building envelope, such as in a window. In some instances, self-contained room conditioning units can include a heat pump and can straddle the envelope opening such that a first heat exchanger of the heat pump system is located on an indoor side of the building envelope and a second heat exchanger of the heat pump system is located on an outdoor side of the building envelope.

Such systems can be particularly useful in older buildings that do not have a central heating and/or cooling system or buildings that have a central heating and/or cooling system that is unable to sufficiently meet the heating and/or cooling demand of a given room or other area within the building. As will be appreciated, heat pump systems can often generate condensate via the heat exchanger coils, and traditionally, self-contained room conditioning units including a heat pump are designed to simply permit condensate to drip out of the outdoor portion of the conditioning unit. This can be problematic, however. For example, it can be undesirable for water to drip below the outdoor portion of a conditioning unit, such as if a sidewalk is located below the outdoor portion of the conditioning unit. This can be particularly undesirable in colder climates, where icicles or ice sheets can form from the dripping condensate.

Moreover, such systems typically have an outdoor portion that is exposed to the elements, wherein the outdoor portion houses the outdoor heat exchanger coil. Thus, the outdoor heat exchanger coil can, over time, become dirty, which can negatively impact the heat transferability of the outdoor heat exchanger coil, thereby reducing the overall heat exchanger efficiency and energy efficiency of the unit's heat pump. Typically, such systems require regular cleaning by the user or a technician to ensure efficient operation of the unit's heat pump. However, the heat exchanger coil, which is located in the outdoor portion and is thus typically suspended some distance outside of a window, can be cumbersome and difficult to clean.

BRIEF DESCRIPTION OF THE FIGURES

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various aspects of the presently disclosed subject matter and serve to explain the principles of the presently disclosed subject matter. The drawings are not intended to limit the scope of the presently disclosed subject matter in any manner.

FIG. 1A illustrates a first perspective view of an example room conditioning unit in accordance with one or more embodiments of the present disclosure.

FIG. 1B illustrates a second perspective view of an example room conditioning unit in accordance with one or more embodiments of the present disclosure.

FIG. 1C illustrates an elevation view from an indoor portion perspective of an example room conditioning unit in accordance with one or more embodiments of the present disclosure.

FIG. 1D illustrates an elevation view from an outdoor portion perspective of an example room conditioning in accordance with one or more embodiments of the present disclosure.

FIG. 1E illustrates a top view of an example room conditioning unit in accordance with one or more embodiments of the present disclosure.

FIG. 1F illustrates a bottom view of an example room conditioning unit in accordance with one or more embodiments of the present disclosure.

FIG. 1G illustrates a first side view of an example room conditioning unit in accordance with one or more embodiments of the present disclosure.

FIG. 1H illustrates a second side view of an example room conditioning unit in accordance with one or more embodiments of the present disclosure.

FIG. 1I illustrates a cross-sectional view of an example room conditioning unit in accordance with one or more embodiments of the present disclosure.

FIGS. 2A and 2B illustrate an elevation view and a side view, respectively, of an example room conditioning unit installed in a window in accordance with one or more embodiments of the present disclosure.

FIG. 3A illustrates a side view of an indoor portion of an example room conditioning unit in accordance with one or more embodiments of the present disclosure.

FIG. 3B illustrates a side view of an indoor portion of an example room conditioning unit with the door of an access panel removed in accordance with one or more embodiments of the present disclosure.

FIG. 3C illustrates a side view of an indoor portion of an example room conditioning unit with the side of the indoor portion removed from clarity of illustration in accordance with one or more embodiments of the present disclosure.

FIG. 3D illustrates a perspective view of an example room conditioning unit with the side walls of the room conditioning unit removed from clarity of illustration in accordance with one or more embodiments of the present disclosure.

FIGS. 4A and 4B illustrate an example filter assembly in accordance with one or more embodiments of the present disclosure.

FIGS. 5A-5C illustrate views of an example outdoor portion having various water discharge configurations in accordance with one or more embodiments of the present disclosure.

FIGS. 6A and 6B illustrate an example spray bar of a water discharge configuration in accordance with one or more embodiments of the present disclosure.

FIG. 7 illustrates a perspective view of an example room conditioning unit with the side walls of the room conditioning unit removed from clarity of illustration in accordance with one or more embodiments of the present disclosure.

DETAILED DESCRIPTION

The present disclosure is generally directed to condensate removal systems and methods for self-contained heat pump room conditioning units (referenced herein as “room conditioning unit” or “unit”).

Typical room conditioning units may transfer heat from/to a conditioned space to the environment outside of the conditioned space. In some instances, room conditioning units (e.g., heat pumps or the like) may generate condensate. The systems and methods disclosed herein may be configured to manage the condensate generated by the room conditioning units. For example, the systems and methods disclosed herein may be configured to collect and disperse (by one or more nozzles or spray bars) the condensate so as to prevent the condensate from dripping out of the outdoor portion of the conditioning unit, which may also prevent the condensate from forming icicles or ice sheets about the outdoor portion of the conditioning unit.

The room conditioning unit can include an indoor portion having an indoor heat exchanger coil, an outdoor portion having an outdoor heat exchanger coil, and a bridge portion connecting the indoor and outdoor portions being configured to extend across the opening of the building envelope (e.g., across a windowsill). In some instances, the room conditioning unit can include one or more condensate removal systems for safely and efficiently discharging condensate that can accumulate during operation of the heat pump. For example, the disclosed condensate removal systems can decrease or eliminate the likelihood that an icicle or ice sheet will form from the condensate on the outdoor portion of the room conditioning unit. Moreover, the room conditioning unit can include an outdoor coil cleaning system that can reduce or eliminate the need for a user or technician to clean the outdoor coil.

In certain embodiments, condensate may be pumped from the indoor portion and may be dispersed on the outdoor heat exchanger coil. This may both remove the condensate from the indoor portion and cool the outdoor heat exchanger coil. In some embodiments, the condensate is dispersed via one or more nozzles disposed between a fan and the outdoor heat exchanger coil such that condensate dispersed from the one or more nozzles is blown by the fan into the outdoor heat exchanger coil. In other embodiments, the condensate is dispersed via a pipe having a plurality of apertures. In some instances, the pipe is disposed between a fan and the outdoor heat exchanger coil such that condensate dispersed from the plurality of apertures is blown by the fan into the outdoor heat exchanger coil. In other instances, the pipe is located above the outdoor heat exchanger coil such that condensate dispersed from the plurality of apertures is dispersed directly onto the outdoor heat exchanger coil.

In certain embodiments, condensate may be pumped from the outdoor portion and may be dispersed on the indoor heat exchanger coil. This may both remove the condensate from the outdoor portion and provide humidity to the air provided by the indoor portion. In some embodiments, the condensate is dispersed via one or more nozzles disposed between a fan and the indoor heat exchanger coil such that condensate dispersed from the one or more nozzles is blown by the fan into the indoor heat exchanger coil. In other embodiments, the condensate is dispersed via a pipe having a plurality of apertures. In some instances, the pipe is disposed between a fan and the indoor heat exchanger coil such that condensate dispersed from the plurality of apertures is blown by the fan into the indoor heat exchanger coil. In other instances, the pipe is located above the indoor heat exchanger coil such that condensate dispersed from the plurality of apertures is dispersed directly onto the indoor heat exchanger coil.

These and other aspects of the present disclosure are described below with reference to the accompanying figures. Other aspects and features of the present disclosure will become apparent to those of ordinary skill in the art upon reviewing the following description of specific examples of the present disclosure in concert with the figures. While features of the present disclosure may be discussed relative to certain examples and figures, all examples of the present disclosure can include one or more of the features discussed herein. Further, while one or more examples may be discussed as having certain advantageous features, one or more of such features may also be used with the various other examples of the disclosure discussed herein. In similar fashion, while examples may be discussed below as devices, systems, or methods, it is to be understood that such examples can be implemented in various devices, systems, and methods of the present disclosure.

Although various aspects of the disclosed technology are explained in detail herein, it is to be understood that other aspects of the disclosed technology are contemplated. Accordingly, it is not intended that the disclosed technology is limited in its scope to the details of construction and arrangement of components expressly set forth in the following description or illustrated in the drawings. The disclosed technology can be implemented and practiced or carried out in various ways. In particular, the presently disclosed subject matter is described in the context of being systems and methods for use with a heat pump water heating system. The present disclosure, however, is not so limited, and can be applicable in other contexts. The present disclosure can, for example, include devices and systems for use with air conditioning systems, refrigeration systems, pool water heat systems, and other similar systems. Furthermore, although described in the context of being a water heater, the disclosed technology can be configured to heat fluids other than water. For example, the disclosed technology can be implemented in various commercial and industrial fluid heating systems used to heat fluids other than water. Accordingly, when the present disclosure is described in the context of a heat pump water heater system, it will be understood that other implementations can take the place of those referred to.

It should also be noted that, as used in the specification and the appended claims, the singular forms “a.” “an,” and “the” include plural references unless the context clearly dictates otherwise. References to a composition containing “a” constituent is intended to include other constituents in addition to the one named.

Also, in describing the disclosed technology, terminology will be resorted to for the sake of clarity. It is intended that each term contemplates its broadest meaning as understood by those skilled in the art and includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.

Ranges may be expressed herein as from “about” or “approximately” or “substantially” one particular value and/or to “about” or “approximately” or “substantially” another particular value. When such a range is expressed, the disclosed technology can include from the one particular value and/or to the other particular value. Further, ranges described as being between a first value and a second value are inclusive of the first and second values. Likewise, ranges described as being from a first value and to a second value are inclusive of the first and second values.

Herein, the use of terms such as “having.” “has,” “including,” or “includes” are open-ended and are intended to have the same meaning as terms such as “comprising” or “comprises” and not preclude the presence of other structure, material, or acts. Similarly, though the use of terms such as “can” or “may” are intended to be open-ended and to reflect that structure, material, or acts are not necessary, the failure to use such terms is not intended to reflect that structure, material, or acts are essential. To the extent that structure, material, or acts are presently considered to be essential, they are identified as such.

It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Moreover, although the term “step” can be used herein to connote different aspects of methods employed, the term should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly required. Further, the disclosed technology does not necessarily require all steps included in the methods and processes described herein. That is, the disclosed technology includes methods that omit one or more steps expressly discussed with respect to the methods described herein.

The components described hereinafter as making up various elements of the disclosed technology are intended to be illustrative and not restrictive. Many suitable components that would perform the same or similar functions as the components described herein are intended to be embraced within the scope of the disclosed technology. Such other components not described herein can include, but are not limited to, similar components that are developed after development of the presently disclosed subject matter.

Referring now to the drawings, and particularly to FIGS. 1A-1I, in certain embodiments, a self-contained heat pump room conditioning unit 100 can include an indoor portion 102, an outdoor portion 104, and a bridge portion 106 connecting the indoor portion 102 and the outdoor portion 104. As shown in FIG. 1I, the indoor portion 102 may include an outer facing side 116, lateral sides 110, 112, a top 114, and an inner facing side 108.

As shown in FIG. 1I, the self-contained heat pump room conditioning unit 100 can house and/or include an indoor heat exchanger coil 118 (also referenced as indoor coil 118) and a blower 120 (or fan). In some instances, the outdoor portion 104 can include an outdoor heat exchanger coil 122 (also references as outdoor coil 122), a compressor, an expansion valve, and a fan 124. The indoor coil 118, the outdoor coil 122, the compressor, and the expansion valve (among other components) can be fluidly connected via tubing configured to pass a refrigerant therethrough, thereby forming the self-contained heat pump room conditioning unit 100, which functions as a vapor compression cycle system. While the compressor and/or the expansion valve can be located within the indoor portion 102 or even the bridge portion 106, the self-contained heat pump room conditioning unit 100 is illustrated as having the compressor and the expansion valve located in the outdoor portion 104, which can help reduce noise (and heat output during cooling mode) into the indoor space. The self-contained heat pump room conditioning unit 100 can further include a reversing valve (e.g., a four-way valve, not shown) configured to reverse the flow direction of the refrigerant through the self-contained heat pump room conditioning unit 100, thereby transitioning the self-contained heat pump room conditioning unit 100 between a heating mode, a cooling mode, and/or a defrosting mode.

In certain embodiments, the indoor portion 102 can include an indoor base pan 126. Referring to FIG. 1I in particular, at least a portion of the inner-facing side 108 and/or the lateral sides 110, 112 of the indoor portion 102 can include an air inlet 128 configured to intake air and an air outlet 130 configured to discharge air. The blower 120 can be configured to pull air into the indoor portion 102 via the air inlet 128 and move the air across the indoor coil 118 to effect heat transfer between the refrigerant flowing through the indoor coil 118 and the passing air. The blower 120 can subsequently discharge air into the indoor space via the air outlet 130. In some instances, the indoor base pan 126 can be sloped to bias the flow of condensate to a desired location for subsequent discharge or removal from the indoor base pan 126, which can help reduce the amount of maintenance a user is required to perform.

The outdoor portion 104 can include an outdoor base pan 132, an outer-facing side 134, an inner-facing side 136, opposing lateral sides 138, 139, and a top 140. At least a portion of the inner-facing side 136 and/or one or both of the opposing lateral sides 138, 139 can include louvers 17, 172, which act as air inlets. More so, the outer-facing side 134 of the outdoor portion 104 can include louvers 142 or the like, which act as an air outlet. During operation, the fan 124 can be configured to pull air into the outdoor portion 104 via the louvers 170, 172 (or other air inlet(s)), pass the air across the outdoor coil 122 to effect heat transfer between the refrigerant flowing through the outdoor coil 122 and the passing air, and discharge the air via the louver 142 the outer-facing side 134. In some instances, the outdoor base pan 132 can be sloped to bias the flow of condensate to one or more desired locations for subsequent discharge or removal from the indoor base pan 126. A drain valve 148 may be in communication with the outdoor base pan 132. In certain embodiments, the outdoor coil 122 and/or at least some of the fan 124 (e.g., the fan blades) can be located in an outdoor coil housing 144 (e.g., as shown in FIG. 1I), which can help protect the outdoor coil 122 from dirt, which can help improve the heat transferability of the outdoor coil 122 and/or reduce the frequency with which the outdoor coil 122 requires cleaning.

The bridge portion 106 can include insulation to prevent unwanted heat transfer between outdoor and the indoor space. The insulation can also reduce noise and vibration associated with the self-contained heat pump room conditioning unit 100, particularly from the indoor side. The bridge portion 106 can include a pathway for refrigerant tubing, power cables, and/or water pump tubing. In some instances, the bridge portion 106 can be located at or near the top of the indoor portion 102 and the outdoor portion 104 such that the self-contained heat pump room conditioning unit 100 has a generally saddle shape. The self-contained heat pump room conditioning unit 100 may be any suitable size, shape, or configuration. Accordingly, the self-contained heat pump room conditioning unit 100 can be configured to straddle a window sill or another opening in a building envelope, such as is illustrated in FIGS. 2A and 2B.

In certain embodiments, the width of the outdoor portion 104 and/or the bridge portion 106 can be less than a width of the indoor portion 102. For example, the width of the outdoor portion 104 and/or the bridge portion 106 can be less than the width of a standard window opening, whereas the width of the indoor portion 102 can be greater than or approximately equal to the width of a standard window opening. As specific examples, the outdoor portion 104 and/or the bridge portion 106 can have a width of approximately 20 inches, and the indoor portion 102 can have a width of approximately 26 inches. The bridge portion 106 can have a length sufficiently long to extend across a standard windowsill. As a specific example, the bridge portion 106 can have a length of approximately 12 inches. The length of the bridge portion 106 can also serve to separate the inner-facing side 116 of the indoor portion 102 from the wall of the building envelope and/or to separate the inner-facing side 136 of the outdoor portion 104 from the building. The indoor portion 102, the bridge portion 106, and the outdoor portion 104 may be any suitable size, shape, or configuration.

The self-contained heat pump room conditioning unit 100 can include a controller, which can include one or more processors and memory having instructions stored thereon that, when executed by the one or more processors, cause the controller to perform certain methods. For example, the controller can be configured to receive data inputs from a user interface and/or one or more sensors (e.g., temperature sensor(s), humidity sensor(s)) and can be configured to output instructions for certain components to operate. For example, the controller can be configured to output instructions for the compressor, the reversing valve, the fan 124, and/or the blower 120 to operate based at least in part on a current operating mode of the self-contained heat pump room conditioning unit 100 (e.g., heating mode, cooling mode, defrosting mode) and/or received sensor data from one or more of the sensors.

As will be appreciated, the outdoor coil can become dirty over time, which can negatively impact the heat transferability of the outdoor coil 122, thereby reducing the overall heat exchanger efficiency and energy efficiency of the unit's heat pump. In certain embodiments, to reduce or eliminate the frequency with which a user or technician may clean the outdoor coil 122, the self-contained heat pump room conditioning unit 100 can include an outdoor coil cleaning system. During cooling mode, the indoor coil 118 can sometimes create condensate, which is subsequently collected by the indoor base pan 126. In certain embodiments, the self-contained heat pump room conditioning unit 100 can be configured to pump the collected condensate from the indoor base pan 126 to the outdoor portion 104 and discharge the collected water on the outdoor coil 122.

Referring now to FIGS. 3A-3D, in certain embodiments, the indoor portion 102 can include an access panel 302. FIG. 3A illustrates the indoor portion 102 with the door of the access panel 302 closed, and FIG. 3B illustrates the door of the access panel 302 removed. FIG. 3C illustrates the access panel 302 with the sidewall of the indoor portion 102 removed to more clearly show aspects of the outdoor coil cleaning system.

The access panel 302 can be easily removed, revealing a pump 304 and tubing 306. One piece of the tubing 306 can connect the inlet of the pump 304 to a filter assembly 308 disposed about the indoor base pan 126, and another piece of tubing 306 can connect the outlet of the pump 304 to a discharge location in the outer portion 130. For example, the tubing 306 may extend through the bridge portion 106 to the outer portion 130.

In certain embodiments, the filter assembly 308 can be easily removable from the access panel 302 to facilitate easy cleaning of the filter assembly 308 (e.g., to prevent clogging). As shown in FIGS. 4A and 4B, the filter assembly 308 can include a filter housing 402 and a filter 404 (e.g., a screen). The filter assembly 308 can include an attachment portion 406 configured to detachably attach the filter housing 402 to the indoor base pan 126. Alternatively, or in addition, the filter housing 402 and/or filter 404 can be configured to detachably attach to the indoor base pan 126. The filter assembly 308 can include a discharge aperture 408 configured to fluidly attach to the pump 304 via the tubing 306.

In certain embodiments, after the pump 304 draws in water from the filter assembly 308, the pump 304 can push the water through the bridge portion 106 via the tubing 306 and to a discharge location at or near the outdoor coil 122 via a water dispersing mechanism. The water dispersing mechanism may be any known device or system that is configured to disperse water over an area. In some instances, the water dispersing mechanism includes one or more nozzles. In other instances, the water dispersing mechanism includes a pipe having a plurality of apertures (which also may include nozzles).

Referring to FIGS. 5A-5C, the discharge location can be within the outdoor coil housing 144. The tubing 306 can fluidly connect to one or more nozzles, a sample of which is indicated as nozzle 502, as shown in FIG. 5B. While two nozzles, including nozzle 502, are illustrated, any number of nozzles can be included. For example, one, three, four, five, six, or more nozzles can be included, and the nozzles can be arranged in series, parallel, or series-parallel configurations.

In certain embodiments, the one or more nozzles may be positioned in an area 503 between the outdoor heat exchanging coil 122 and the fan 124. In this manner, the water dispersed from the one or more nozzles 502 may fall due to gravity and/or be sprayed by the nozzles into the area 503. The condensate may then be distributed about the surface of the outdoor heat exchanging coil 122 via the air being moved by the fan 124, which may result in the disbursement of the condensate over the surface area of all or a substantial portion of the outdoor heat exchanging coil 122. In this manner, the condensate is not merely dripped onto one area of the outdoor heat exchanging coil 122. Rather, by increasing the area of distribution of the condensate over the outdoor heat exchanging coil 122 as a result of water droplets falling from gravity from the nozzles 502 and/or being sprayed by the nozzles 502 and then being blown into and about the outdoor heat exchanging coil 122 from the fan 124, the outdoor heat exchanging coil 122 may be more efficiently cooled. The nozzle or nozzles can be arranged in any desired configuration and can be positioned so as to direct water at a predetermined location on or about the outdoor coil 122. For example, the nozzle(s) can be arranged to substantially evenly spray the outdoor coil 122, or the nozzle(s) can be configured to spray a predetermined portion of the outdoor coil 122, such as the top portion of the outdoor coil 122.

Alternatively, or in addition, the tubing 306 can fluidly connect to a spray bar, which can be a bar (or pipe) having an inlet 506 and a plurality of apertures through which water can be discharged and directed toward the outdoor coil 122. An example spray bar 504 is shown in FIG. 5C and is shown in more detail in FIGS. 6A and 6B. In certain embodiments, the spray bar 504 can have the inlet 506 at a generally central location along the length of the spray bar 504. The apertures of the spray bar 504, a sample of which is indicated as aperture 602 in FIG. 6B, can be the same size or can differ in size. For example, the size of the apertures can increase as the distance from the inlet increases or vice versa. In such a configuration, the size of the apertures can change to help facilitate an even discharge of water along the length of the spray bar 504. For example, the spray bar 504 may have a longitudinal length extending substantially about the width of the outdoor coil 122. In some instances, a first aperture may be disposed about a first longitudinal location on the spray bar 504 that is closer to a longitudinal center of the spray bar 504 than that of a second aperture disposed about a second longitudinal location on the spray bar 504. Each of the apertures can have a circular, ovular, or any other suitable shaped cross section. Further, in some embodiments, the apertures can be slits.

While the spray bar 504 is shown as having a single inlet 506 at a generally central location (e.g., near the longitudinal center of the spray bar 504), the inlet can be position at any location along the spray bar 504. Alternatively, or in addition, the spray bar 504 can have multiple inlets, such as inlets at opposing ends of the spray bar. In such a configuration, the apertures can be smallest near the ends of the spray bar 504, and the size of the apertures can increase toward the center of the spray bar 504, or vice versa.

The apertures can be arranged in any desired configuration and can be positioned so as to direct water at a predetermined location on or about the outdoor coil 122. For example, the apertures (and/or nozzle) can be arranged to substantially evenly spray the outdoor coil 122, or the apertures (and/or nozzles) can be configured to spray a predetermined portion of the outdoor coil 122, such as the top portion of the outdoor coil 122.

In a manner, similar to the nozzles discussed above with reverence to FIG. 5B, the spray bar 504 may be positioned in the area 503 between the outdoor heat exchanging coil 122 and the fan 124. In some instances, the water dispersed from the apertures may fall due to gravity, and then will be distribute about the surface of the outdoor heat exchanging coil 122 via the air being moved by the fan 124. In this manner, the condensate is not merely dripped onto one area of the outdoor heat exchanging coil 122. Rather, by increasing the area of distribution of the condensate over the outdoor heat exchanging coil 122 as a result of water droplets falling from gravity from the spray bar 504 and then being blown into the outdoor heat exchanging coil 122 from the fan 124, the outdoor heat exchanging coil 122 is more efficiently cooled.

In certain embodiments, one or more water sensors can be located on or near the filter assembly 308 and/or the indoor base pan 126. A first water sensor can be configured to detect a first water level corresponding to an amount of water sufficient to be pumped to the outdoor coil 122. A second water sensor can be configured to detect a maximum water level at which the controller can be programmed to disable a compressor 508. Thus, the second water sensor can determine that a maximum amount of water has collected in the indoor base pan 126. As a result, the compressor 508 may be disabled (e.g., turned off) to prevent further accumulation of condensate, which may help avoid the potential for an eventual indoor leak or spillage.

In operation, the controller can be configured to output instructions for the pump 304 to begin pumping water in response to receiving a signal from the first water sensor, which can indicate that there is sufficient water in the indoor base pan 126 to be discharged onto the outdoor coil 122. The controller can be configured to operate for a predetermined duration (e.g., 30 seconds) or until the first water sensor indicates that the water level within the indoor base pan 126 has dropped below a second predetermined water level associated with insufficient water being available in the indoor base pan 126. Alternatively. or in addition, the controller can be configured to operate the pump 304 for a predetermined duration at predetermined intervals, while the self-contained heat pump room conditioning unit 100 is operating in cooling mode (e.g., for 25 seconds every 9 minutes).

In certain embodiments, the self-contained heat pump room conditioning unit 100 can include a reservoir configured to hold a cleaning solution, and the cleaning solution can be pumped and dispersed onto the outdoor coil 122 by itself or in a mix with condensate drawn from the indoor base pan 126. The reservoir can be located in the access panel 302. Alternatively, the reservoir can be located at another location within the indoor portion 102, in the bridge portion 106, or in the outdoor portion 104.

Alternatively. or in addition, and referring to FIG. 7, the self-contained heat pump room conditioning unit 100 can pump condensate from the outdoor portion 104 to the indoor portion 102. That said, the self-contained heat pump room conditioning unit 100 can operate opposite what was described above. For example, the self-contained heat pump room conditioning unit 100 can include a pump 702, a filter assembly 704, and tubing 706. In certain embodiments, the pump 702 may have a similar form and function as pump 304 (or can be a different pump), the filter assembly 704 may have a similar form and function as filter assembly 308 (or can be a different filter assembly), and/or the tubing 706 may have the same form and function as tubing 306 (or can be different tubing). In this manner, when the self-contained heat pump room conditioning unit 100 is operating in defrosting mode, melted ice from the outdoor coil 122 can accumulate in the outdoor base pan 132. In certain embodiments, to remove this accumulated water from the outdoor base pan 132, the pump 702 can be configured to transport the water from the outdoor base pan 132 to the indoor portion 102, where the condensate can be discharged onto the indoor coil 118. The water on the indoor coil 118 can then evaporate when the self-contained heat pump room conditioning unit 100 is operating in the heating mode. Thus, water can be removed from the outdoor base pan 132 and humidity can be added to the indoor space. The water can be discharged onto the indoor coil 118 using the same or substantially the same configurations as those discussed herein with respect to discharging water on the outdoor coil 122. For example, the water can be discharged onto the indoor coil using nozzles similar to nozzle 502, a spray bar similar to spray bar 504, or the like.

In certain embodiments, one or more water sensors can be located in or near the outdoor base pan 132 and can be configured to detect when a sufficient amount of water is present in the outdoor base pan 132 for pumping to the indoor coil 118. The controller can be configured to receive a signal from the water sensor and output instructions for the pump 702 to operate when there is sufficient water in the outdoor base pain 132. Alternatively, or in addition, the controller can be configured to operate the pump 702 for predetermined durations and/or at predetermined intervals.

Although the pump 702 and the filter assembly 704 are shown as being located in the indoor portion 102, one or both can be located at different locations, such as in the bridge portion 106 or the outdoor portion 104. Locating the filter assembly 704 in the outdoor base pan 132 can help prevent debris from entering the tubing 706, but such a location can also make it more difficult for a user to clean the filter assembly 704. In this manner, in some instances, the filter assembly 704 may be located in the indoor portion 102 for ease of access. More so, the systems and methods disclosed herein may be reversed. For example, condensate may be pumped from the outdoor portion and may be dispersed on the indoor heat exchanger coil using the nozzles and pipes having a plurality of apertures disclosed herein. This may both remove the condensate from the outdoor portion and provide humidity to the air provided by the indoor portion.

Alternatively, or in addition, the outdoor base pan 132 can include a non-stick coating. For example, some or all of the outdoor base pan 132 can be coated in polytetrafluoroethylene, e.g., Teflon®, or a similar material. Such coatings can help promote a cleaner environment within the outdoor portion 104, as it can be more difficult for dirt, grime, and debris to stick to the outdoor base pan 132 (e.g., as compared to the outdoor base pan 132 without such a coating). Further, polytetrafluoroethylene has a high chemical compatibility with plastic materials, has high abrasion resistance, has a large operating temperature range, and is compatible with many coil cleaning materials. A non-stick coating on the outdoor base pan 132 can promote discharge of water or other liquids due to the beading effect associated with water on a non-stick coating. Polytetrafluoroethylene and other non-stick coatings also have a low thermal conductivity and thermal diffusivity, which can reduce the likelihood of water refreezing while it located on the outdoor base pan 132 before being discharged, and the effective conduction area of a water droplet on the non-stick coating is less (as compared to the outdoor base pan 132 without such a coating) due to the beading effect.

Exemplary Embodiments

Embodiment 1. An air conditioning unit for use in an opening of a building, the air conditioning unit comprising: an indoor portion configured to be positioned within an internal portion of the building and having an indoor heat exchanging coil; an outdoor portion configured to be positioned about an external portion of the building and having an outdoor heat exchanging coil; a pump; tubing connected to the pump; and a water dispersing mechanism, wherein the pump and the tubing are configured to pump condensate from one of the indoor portion and the outdoor portion to the water dispersing mechanism disposed at the other of the indoor portion and the outdoor portion.

Embodiment 2. The air conditioning unit of embodiment 1, wherein the pump and the tubing are configured to pump the condensate from the indoor portion to the water dispersing mechanism disposed at the outdoor portion.

Embodiment 3. The air conditioning unit of embodiments 1 or 2, wherein the outdoor portion comprises a fan configured to provide airflow out of the outdoor portion, and wherein the water dispersing mechanism is configured to disperse the condensate into a space between the fan and the outdoor heat exchanging coil such that the fan disperses the condensate onto the outdoor heat exchanging coil.

Embodiment 4. The air conditioning unit of any one of embodiments 1 to 3, wherein the water dispersing mechanism comprises one or more nozzles, a pipe having a plurality of apertures, or a combination thereof.

Embodiment 5. The air conditioning unit of any one of embodiments 1 to 4, wherein the water dispensing mechanism comprises the pipe having a plurality of apertures, and wherein the plurality of apertures comprises a first aperture having a first size and a second aperture having a second size that is smaller than the first size.

Embodiment 6. The air conditioning unit of any one of embodiments 1 to 5, wherein the first aperture is disposed at a first longitudinal location on the pipe, wherein the second aperture is disposed at a second longitudinal location on the pipe, and wherein the first longitudinal location on the pipe is closer to a longitudinal center of the pipe than that of the second longitudinal location on the pipe.

Embodiment 7. The air conditioning unit of any one of embodiments 1 to 6, wherein each of the apertures comprise a circle, an oval, and/or a slit.

Embodiment 8. The air conditioning unit of any one of embodiments 1 to 7, wherein the indoor portion includes a base pan configured to collect the condensate, and wherein the pump is configured to pump the condensate from the base pan to the water dispensing mechanism.

Embodiment 9. The air conditioning unit of any one of embodiments 1 to 8, wherein the water dispensing mechanism comprises a filter configured to filter the condensate before it enters the tubing.

Embodiment 10. An air conditioning unit for use in an opening of a building, the air conditioning unit comprising: an indoor portion configured to be positioned within an internal portion of the building and having an indoor heat exchanging coil; an outdoor portion configured to be positioned about an external portion of the building and having an outdoor heat exchanging coil; a fan disposed in within the outdoor portion and configured to move air past the outdoor heat exchanging coil; and a water dispensing mechanism, wherein the indoor portion includes a base pan configured to collect condensate, and wherein the water dispensing mechanism is configured to move the condensate from the base pan to a space between the fan and the outdoor heat exchanging coil.

Embodiment 11. The air conditioning unit of embodiment 10, wherein the water dispensing mechanism comprises a pump, tubing, and a filter assembly, and wherein the pump is configured to pump the condensate through the filter assembly and the tubing.

Embodiment 12. The air conditioning unit of embodiments 10 or 11, wherein the water dispersing mechanism comprises one or more nozzles, a pipe having a plurality of apertures, or a combination thereof.

Embodiment 13. The air conditioning unit of any one of embodiments 10 to 12, wherein the plurality of apertures comprises a first aperture having a first size and a second aperture having a second size that is smaller than the first size.

Embodiment 14. The air conditioning unit of any one of embodiments 10 to 13, wherein the first aperture is disposed at a first longitudinal location on the pipe, wherein the second aperture is disposed at a second longitudinal location on the pipe, and wherein the first longitudinal location on the pipe is closer to a longitudinal center of the pipe than that of the second longitudinal location on the pipe.

Embodiment 15. The air conditioning unit of any one of embodiments 10 to 14, wherein each of the apertures comprise a circle, an oval, and/or a slit.

Embodiment 16. The air conditioning unit of any one of embodiments 10 to 15, wherein the one or more nozzles are configured to spray the condensate within the outdoor portion about the outdoor heat exchanging coil such that the fan disperses the condensate about the outdoor heat exchanging coil and out of the outdoor portion.

Embodiment 17. An air conditioning unit for use in an opening of a building, the air conditioning unit comprising: an indoor portion configured to be positioned within an internal portion of the building and having an indoor heat exchanging coil; an outdoor portion configured to be positioned about an external portion of the building and having an outdoor heat exchanging coil; a fan disposed in within the indoor portion and configured to move air past the indoor heat exchanging coil; and a water dispensing mechanism, wherein the outdoor portion includes a base pan configured to collect condensate, and wherein the water dispensing mechanism is configured to move the condensate from the base pan to a space between the fan and the indoor heat exchanging coil.

Embodiment 18. The air conditioning unit of embodiment 17, wherein the water dispensing mechanism comprises a pump, tubing, and a filter assembly, and wherein the pump is configured to pump the condensate through the filter assembly and the tubing.

Embodiment 19. The air conditioning unit of embodiments 17 or 18, wherein the water dispersing mechanism comprises one or more nozzles, a pipe having a plurality of apertures, or a combination thereof.

Embodiment 20. The air conditioning unit of any one of embodiments 17 to 19, wherein the plurality of apertures comprises a first aperture having a first size and a second aperture having a second size that is smaller than the first size.

Embodiment 21. The air conditioning unit of any one of embodiments 17 to 20, wherein the first aperture is disposed at a first longitudinal location on the pipe, wherein the second aperture is disposed at a second longitudinal location on the pipe, and wherein the first longitudinal location on the pipe is closer to a longitudinal center of the pipe than that of the second longitudinal location on the pipe.

Embodiment 22. The air conditioning unit of any one of embodiments 17 to 21, wherein each of the apertures comprise a circle, an oval, and/or a slit.

Embodiment 23. The air conditioning unit of any one of embodiments 17 to 22, wherein the one or more nozzles are configured to spray the condensate within the indoor portion about the indoor heat exchanging coil such that the fan disperses the condensate about the indoor heat exchanging coil and out of the indoor portion.

Embodiment 24. An air conditioning unit comprising the combination of any one of embodiments 1 to 23.

While the present disclosure has been described in connection with a plurality of exemplary aspects, as illustrated in the various figures and discussed above, it is understood that other similar aspects can be used, or modifications and additions can be made to the described subject matter for performing the same function of the present disclosure without deviating therefrom. In this disclosure, methods and compositions were described according to aspects of the presently disclosed subject matter. But other equivalent methods or compositions to these described aspects are also contemplated by the teachings herein. Therefore, the present disclosure should not be limited to any single aspect, but rather construed in breadth and scope in accordance with the appended claims.

Moreover, the various diagrams and figures presented herein are for illustrative purposes and are not to be considered exhaustive. That is, the systems described herein can include one or more additional components, such as various valves, expansions tanks, and the like, as will be appreciated by one having ordinary skill in the art.

Condensate Transfer Systems for Self-Contained Heat Pump Room Conditioning Units

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