The present disclosure pertains to Heating, Ventilation, and/or Air Conditioning (HVAC) systems. More particularly, the present disclosure pertains to HVAC controllers, such as thermostats.
Heating, Ventilation, and/or Air Conditioning (HVAC) systems are often used to control the comfort level within a building or other structure. Such HVAC systems typically include an HVAC controller that controls various HVAC components of the HVAC system in order to affect and/or control one or more environmental conditions within the building. In many cases, the HVAC controller is mounted to an internal wall of the building and provides control signals to various HVAC components of the HVAC system, sometimes via a number of control wires that extend through the wall. Improvements in the hardware, user experience, and functionality of such HVAC controllers would be desirable.
The present disclosure pertains generally to an HVAC controller with a temperature sensor. In some cases, the HVAC controller may be a thermostat. An HVAC controller may include a housing, a display, a printed wiring board, a flextail, and a temperature sensor such as a thermistor. The housing of the HVAC controller may be configured to house the display, the printed wiring board, the flextail, and the temperature sensor. The flextail may be a flexible circuit, a ribbon cable or any other suitable fixable circuit. The flextail may extend from, for example, the display or other component of the HVAC controller, along the interior surface of the housing, and connect to a connector on the printed wiring board. The temperature sensor may be mounted on the flextail and connected to the printed circuit board via the flex tail or other connection. In some cases, the temperature sensor may be positioned on the flextail such that when the flextail is connected to the printed wiring board, the temperature sensor is positioned adjacent a lower part of the housing, where less internal heat generated by the internal electrical components of the HVAC controller will reside.
The preceding summary is provided to facilitate an understanding of some of the features of the present disclosure and is not intended to be a full description. A full appreciation of the disclosure can be gained by taking the entire specification, claims, drawings, and abstract as a whole.
The disclosure may be more completely understood in consideration of the following description of various illustrative embodiments of the disclosure in connection with the accompanying drawings, in which:
While the disclosure is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit aspects of the disclosure to the particular illustrative embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure.
The following description should be read with reference to the drawings wherein like reference numerals indicate like elements. The drawings, which are not necessarily to scale, are not intended to limit the scope of the disclosure. In some of the figures, elements not believed necessary to an understanding of relationships among illustrated components may have been omitted for clarity.
All numbers are herein assumed to be modified by the term “about”, unless the content clearly dictates otherwise. The recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5).
As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” include the plural referents unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
It is noted that references in the specification to “an embodiment”, “some embodiments”, “other embodiments”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is contemplated that the feature, structure, or characteristic may be applied to other embodiments whether or not explicitly described unless clearly stated to the contrary.
The present disclosure is directed generally at building automation systems. Building automation systems are systems that control one or more operations of a building. Building automation systems can include HVAC systems, security systems, fire suppression systems, energy management systems and other systems. While HVAC systems with HVAC controllers are used as an example below, it should be recognized that the concepts disclosed herein can be applied to building automation systems more generally.
It is contemplated that the HVAC controller(s) 18 may be configured to control the comfort level in the building or structure by activating and deactivating the HVAC component(s) 6 in a controlled manner. The HVAC controller(s) 18 may be configured to control the HVAC component(s) 6 via a wired or wireless communication link 20. In some cases, the HVAC controller(s) 18 may be a thermostat, such as, for example, a wall mountable thermostat, but this is not required in all embodiments. Such a thermostat may include (e.g. within the thermostat housing or elsewhere) or have access to one or more temperature sensor(s) (e.g., one or more thermistors or other temperature sensors) for sensing ambient temperature at or near the thermostat. In some instances, the HVAC controller(s) 18 may be a zone controller, or may include multiple zone controllers each monitoring and/or controlling the comfort level within a particular zone in the building or other structure.
In the illustrative HVAC system 4 shown in
In some cases, the system of vents or ductwork 10 and/or 14 may include one or more dampers 24 to regulate the flow of air, but this is not required. For example, one or more dampers 24 may be coupled to one or more HVAC controller(s) 18, and can be coordinated with the operation of one or more HVAC components 6. The one or more HVAC controller(s) 18 may actuate dampers 24 to an open position, a closed position, and/or a partially open position to modulate the flow of air from the one or more HVAC components to an appropriate room and/or zone in the building or other structure. The dampers 24 may be particularly useful in zoned HVAC systems, and may be used to control which zone(s) receives conditioned air from the HVAC component(s) 6.
In many instances, one or more air filters 30 may be used to remove dust and other pollutants from the air inside the building 2. In the illustrative example shown in
In some cases, and as shown in
In some cases, the equipment interface module 34 may include a first temperature sensor 38a located in the return (incoming) air duct 14, and a second temperature sensor 38b located in the discharge (outgoing or supply) air duct 10. Alternatively, or in addition, the equipment interface module 34 may include a differential pressure sensor including a first pressure tap 39a located in the return (incoming) air duct 14, and a second pressure tap 39b located downstream of the air filter 30 to measure a change in a parameter related to the amount of flow restriction through the air filter 30. In some cases, the equipment interface module 34, when provided, may include at least one flow sensor that is capable of providing a measure that is related to the amount of air flow restriction through the air filter 30. In some cases, the equipment interface module 34 may include an air filter monitor. These are just some examples.
When provided, the equipment interface module 34 may be configured to communicate with the HVAC controller 18 via, for example, a wired or wireless communication link 42. In other cases, the equipment interface module 34 may be incorporated or combined with the HVAC controller 18. In some instances, the equipment interface module 34 may communicate, relay or otherwise transmit data regarding the selected parameter (e.g. temperature, pressure, flow rate, etc.) to the HVAC controller 18. In some cases, the HVAC controller 18 may use the data from the equipment interface module 34 to evaluate the system's operation and/or performance. For example, the HVAC controller 18 may compare data related to the difference in temperature (delta T) between the return air side and the discharge air side of the HVAC system 4 to a previously determined delta T limit stored in the HVAC controller 18 to determine a current operating performance of the HVAC system 4.
In some cases, the HVAC controller 18 may be programmed to communicate over the second network 58 with an external web service hosted by one or more external web server(s) 66. A non-limiting example of such an external web service is Honeywell's TOTAL CONNECT™ web service. The HVAC controller 18 may be configured to upload selected data via the second network 58 to the external web service where it may be collected and stored on the external web server 66. In some cases, the data may be indicative of the performance of the HVAC system 4. Additionally, the HVAC controller 18 may be configured to receive and/or download selected data, settings and/or services sometimes including software updates from the external web service over the second network 58. The data, settings and/or services may be received automatically from the web service, downloaded periodically in accordance with a control algorithm, and/or downloaded in response to a user request. In some cases, for example, the HVAC controller 18 may be configured to receive and/or download an HVAC operating schedule and operating parameter settings such as, for example, temperature set points, humidity set points, start times, end times, schedules, window frost protection settings, and/or the like from the web server 66 over the second network 58. In some instances, the HVAC controller 18 may be configured to receive one or more user profiles having at least one operational parameter setting that is selected by and reflective of a user's preferences. In still other instances, the HVAC controller 18 may be configured to receive and/or download firmware and/or hardware updates such as, for example, device drivers from the web server 66 over the second network 58. Additionally, the HVAC controller 18 may be configured to receive local weather data, weather alerts and/or warnings, major stock index ticker data, traffic data, and/or news headlines over the second network 58. These are just some examples.
Depending upon the application and/or where the HVAC user is located, remote access and/or control of the HVAC controller 18 may be provided over the first network 54 and/or the second network 58. A variety of remote wireless devices 62 may be used to access and/or control the HVAC controller 18 from a remote location (e.g. remote from the HVAC Controller 18) over the first network 54 and/or second network 58 including, but not limited to, mobile phones including smart phones, tablet computers, laptop or personal computers, wireless network-enabled key fobs, e-readers, and/or the like. In many cases, the remote wireless devices 62 are configured to communicate wirelessly over the first network 54 and/or second network 58 with the HVAC controller 18 via one or more wireless communication protocols including, but not limited to, cellular communication, ZigBee, REDLINK™, Bluetooth, WiFi, IrDA, dedicated short range communication (DSRC), EnOcean, and/or any other suitable common or proprietary wireless protocol, as desired.
In some cases, an application program code (i.e. app) stored in the memory of the remote device 62 may be used to remotely access and/or control the HVAC controller 18, but this is not required. The application program code (app) may be downloaded from an external web service, such as the web service hosted by the external web server 66 (e.g. Honeywell's TOTAL CONNECT™ web service) or another external web service (e.g. ITUNES® or Google Play). In some cases, the app may provide a remote user interface for interacting with the HVAC controller 18 at the user's remote device 62. For example, through the user interface provided by the app, a user may be able to change operating parameter settings such as, for example, temperature set points, humidity set points, start times, end times, schedules, window frost protection settings, accept software updates and/or the like. Communications may be routed from the user's remote device 62 to the web server 66 and then, from the web server 66 to the HVAC controller 18. In some cases, communications may flow in the opposite direction such as, for example, when a user interacts directly with the HVAC controller 18 to change an operating parameter setting such as, for example, a schedule change or a set point change. The change made at the HVAC controller 18 may be routed to the web server 66 and then from the web server 66 to the remote device 62 where it may reflected by the application program executed by the remote device 62.
In some cases, a user may be able to interact with the HVAC controller 18 via a user interface provided by one or more web pages served up by the web server 66. The user may interact with the one or more web pages using a variety of internet capable devices to effect a setting or other change at the HVAC controller 18, and in some cases view usage data and energy consumption data related to the usage of the HVAC system 4. In some cases, communication may occur between the user's remote device 62 and the HVAC controller 18 without being relayed through a server such as external server 66. These are just some examples.
In the example shown, the wall mountable connector 84 may also provide a mechanical connection to the thermostat 82 and thus may be used to secure the thermostat 82 in place relative to a vertical surface such as a wall. The wall mountable connector 84 may be considered as being a fully integrated connector, providing electrical and mechanical connections to the thermostat 82 in a compact design that is small enough to be used with a variety of different thermostats and yet affords the ability to easily connect a plurality of field wires to the wall mountable connector 84.
In some instances, the wall mountable connector 84 itself may be secured to an adapter plate 86 that is configured to be secured to an electrical junction box or the like (not illustrated) disposed within the wall. In some cases, the adapter plate 86 may not be used, particularly if the field wires simply exit the wall through a hole in the wall. In some cases, an installer may utilize the adapter plate 86 if there is a large hole in the wall through which the field wires exit, even if there is no junction box within the wall.
In some cases, a wall covering plate 88 may be included to provide an aesthetically pleasing appearance to the thermostat assembly 80. In some instances, for example, the wall covering plate 88 may be larger than the thermostat 82 and may hide blemishes left on the wall from previous thermostat installations. In some cases, a homeowner may, for example, decide they want to install a wall covering plate 88 that has a different shape or design, or perhaps is a different color to match the color of a new thermostat.
The display 96 and the touch screen 98 (e.g., an indium tin oxide (ITO) touch screen or other type of touch screen) may work together to form an interface assembly 97 (e.g., a display assembly). A user may interact with interface assembly 97 in any manner, including, but not limited to, touching the touch screen 98, through interacting with a remote device (not shown), and/or through one or more other interaction mechanisms.
In some instances, the interface assembly 97 may include a 2-dimensional array of pixels that covers the full display area of the display 96. In some instances, the interface assembly 97 may include a display 96 that is a segmented display, which may include a plurality of predefined segments that can be switched on and off to give the appearance of desired characters, icons or other graphical features. In a segmented display, the predefined segments may not be arranged in a full 2-dimensional array of pixels that covers the full display area of the display 96. Rather, at least some of the predefined segments may be elongated, define a symbol or icon, or otherwise do not fall into a simple 2-dimensional array of pixels.
It is contemplated that the display 96 may be any suitable display panel using any suitable display panel technology. For example, the display 96 may include the following types of display panels: Eidophor, Electroluminescent display (ELD), Electronic paper (E Ink, Gyricon), Light emitting diode display (LED), Cathode ray tube (CRT) (Monoscope), Liquid-crystal display (LCD) (TFT, LED, Blue Phase, IPS), Plasma display panel (PDP) (ALiS), Digital Light Processing (DLP), Liquid crystal on silicon (LCoS), Organic light-emitting diode (OLED) (AMOLED), Organic light-emitting transistor (OLET), Surface-conduction electron-emitter display (SED), Field emission display (FED), Laser TV (Quantum dot, Liquid crystal), MEMS display (IMoD, TMOS, DMS), Quantum dot display (QD-LED), Ferro liquid display (FLD), Thick-film dielectric electroluminescent technology (TDEL), Telescopic pixel display (TPD), Laser Phosphor Display (LPD), or other type of display panel.
The back light reflector and display spacer assembly 104 may comprise a frame 105, a backlight guide plate 107, a spacer 109 and/or one or more other components. The components of the back light reflector and display spacer assembly 104 may be made from any material. In one example, the components of the back light reflector and display spacer assembly 104 may be made from plastic, but this is not required. As seen in
In some cases, the back light reflector and display spacer assembly 104 may act as a spacer or space filler between the interface assembly 97 (e.g., the touch screen 98 and/or the display 96) and the PWB 102. In such situations and/or others, the back light reflector and display spacer assembly 104 may receive the touch screen 98 and/or display 96 at a side facing the front cover 92. When the back light reflector and display spacer assembly 104 and the touch screen 98 and/or display 96 received therein are inserted into the front cover 92, the back light reflector and display spacer assembly 104 may help ensure the touch screen 98 and/or display 96 are properly aligned with respect to the opening 94 of the front cover 92.
As seen in
During assembly of the thermostat 82, the various component parts may be assembled in a variety of ways. However, to ensure proper alignment of the various components of the thermostat 82, one example order may include inserting the touch screen 98, the display 96, and the back light reflector and display spacer assembly 104 into the front cover 92. When inserted in the front cover 92, the touch screen 98, the display 96, and/or the back light reflector and display spacer assembly 104 may be entirely or at least partially surrounded by ribs (e.g., rib features 120 described below with respect to
The housing 90 may have an interior side and an exterior side, where one or more electrical components may be enclosed within the housing 90 on the interior side.
The front cover 92 may include one or more latches 122. The latches 122 may be configured to engage latch receivers 132 (discussed with respect to
There may be any number of latches 122 on the front cover 92. In some instances, there may be one (1) latch, two (2) latches, three (3) latches, four (4) latches, six (6) latches, eight (8) latches or other number of latches 122.
The latches 122 may be equally spaced around a perimeter (e.g., the edge 124 or other perimeter) of the front cover 92. Alternatively, one or more of the latches 122 may be irregularly spaced around the perimeter of the front cover 92. As shown in the example depicted in
The front cover 92 may include one or more first guide features 126. The first guide features 126 may be configured to engage associated second guide features 134 (discussed further with respect to
The first guide features 126 may be configured to receive and/or engage second guide features 134 as the front cover 92 and the back cover 93 come into contact with one another. In some instances, one or more of the first guide features 126 may be configured to be received within an associated second guide features 134, but this is not required.
In one example of the first guide features 126, the first guide features 126 may extend from an interior surface of the front cover 92 and form an encircled opening for receiving a second guide features 134, as best shown in
The front cover 92 may include any number of first guide features 126. In some instances, there may be one (1), two (2), three (3), four (4), six (6), eight (8) first guide features 126 or other number of first guide features 126. As shown in
When the housing is fully assembled, the first guide features 126 and the second guide features 134 (discussed below) may facilitate maintaining a desired shape of the housing 90 by providing support between latches to reduce or prevent gaps from forming along locations where edges of the front cover 92 meet edges of the back cover 93. In some cases, without the guide features, permanent gaps may form if the housing sidewalls become deformed as a result of the latches fully engaging the latch receivers.
The latch receivers 132 may be configured to engage latches 122 (discussed above with respect to
In some cases, the second guide features 134 help to prevent the first guide features 126, and thus the sidewall of the front cover 92, from also bending outward, as best shown in
There may be any number of latch receivers 132 on the back cover 93. In some instances, there may be one (1) latch receiver, two (2) latch receivers, three (3) latch receivers, four (4) latch receivers, six (6) latch receivers, eight (8) latch receivers, or other number of latch receiver 132. In one example, there may be the same number of latch receivers 132 as there are latches 122. As shown in
As shown, the back cover 93 may include one or more second guide features 134. The second guide features 134 may be configured to be inserted into and/or engage the first guide features 126 (discussed above with respect to
In some cases, the second guide features 134 may engage associated first guide features 126 prior to the latches 122 fully interacting with associated latch receivers 132 as the front cover 92 and the back cover 93 are brought together. In one example of the second guide features 134, the second guide features 134 may extend from an interior surface of the back cover 93 and may be configured to be received within an encircled opening of the first guide features 126, as best shown in
The back cover 93 may include any number of second guide features 134. In some instances, there may be one (1), two (2), three (3), four (4), six (6), eight (8) second guide features 134 or other number of second guide features 134. As shown in
In some cases, each corner of the interior side of the back cover 93 may include a second guide feature 134 that may or may not take on a similar form as the second guide features 134 that may be positioned along the side edges of the interior side of the back cover 93. In one example, as shown in
When the first guide features 126 and the second guide features 134 are omitted from the housing 90, a gap may form between edge 124 of the front cover 92 and edge 136 of the back cover 93. The gap may form for any of a number of reasons. In one example, the gap may form due to a configuration of the latches 122 (e.g., a configuration configured to prevent ghosting artefacts on walls of the front cover 92), bending or stretching of the wall of the front cover 92 or back cover as the latches 122 engage the latch receivers 132, a thickness of the walls of the housing 90, a material of the housing 90, and/or the gap may form for other reasons. In some cases, the gap may be permanent without the first and second guide features.
The first guide features 126 and the second guide features 134 may be positioned to help prevent or mitigate formation of gaps between the front cover 92 and the back cover 93. The combination of latching mechanisms (e.g., the latches 122 and the latch receivers 132) with guide features (e.g., the first guide features 126 and the second guide features 134) may result in a good stiff connection between parts, while maintaining a gap free interface even when the sidewalls of the front cover 92 are fairly thin.
As shown in
As electronic components of the thermostat 82, such as the touch screen 98, the display 96, electrical components on the PWB 102, and/or other electrical components, may produce heat as those components operate, it has been found to be desirable to separate and/or isolate at least one thermistor of the thermostat from such heat producing components. In one instance, it may be desirable to place at least one thermistor at a location within the thermostat 82 (e.g., within housing 90) that may be less influenced by heat of electronic components operating therein.
Illustratively, ambient temperature around a thermostat may be determined by utilizing measurements from at least two thermistors, where one thermistor is considered a cold thermistor and another thermistor is considered a warmer thermistor. A warmer thermistor may be placed near electronic components producing heat and a cold thermistor may be spaced from the electronic components producing heat. A processor of a thermostat using at least two thermistors may take measurements from the warmer thermistor and the cold thermistor and determine an ambient temperature from a heat flow equation.
It has been determined, relative to other locations within the housing 90 of the thermostat 82, that adjacent a bottom of the interior surface of the front cover 92 is a location that may be minimally affected by heat exhausted from operating electronic components of the thermostat 82 and thus, may be considered an acceptable location to place a cold thermistor. This may be particularly so in the disclosed thermostat where the display 96 and/or the PWB 102 do not extend to a base of the interior surface of the housing 90 (e.g., front cover 92, as seen for example in
To facilitate positioning a thermistor 114 adjacent the interior surface of the housing 90, the thermistor 114 may be placed on a flextail or other flexible circuit extending from the PWB 102, as such flextails may extend adjacent to and/or touch a bottom of the housing 90 that is spaced from the PWB 102 and/or other heat producing components of the thermostat 82. Although the thermistor 114 is discussed as being placed on the display flextail 110, the thermistor 114 may be placed on any flexible circuit including, but not limited to, the screen flextail 108, the display flextail 110, and its own flexible circuit.
As shown in
To facilitate proper and repeatable placement of the thermistor 114, the front cover 92 may include one or more thermistor spacing ribs 116. The thermistor spacing ribs 116 of the front cover 92 may help ensure that the thermistor 114 is positioned at a same location and a same distance from the front cover 92 by contacting the display flextail 110 as it wraps around the PWB 102 to ensure proper bending and/or deformation of the display flextail. It may be desirable to ensure the thermistor 114 is consistently located within the housing 90 during manufacturing so that equations used to determine an ambient temperature around the thermostat accurately determine a temperature at the thermistor 114.
Although not shown, the thermistor 114 on the display flextail 110 may be isolated from electronic components producing heat by an additional material. Illustratively, a heat conducting material may be placed between the thermistor 114 and a wall of the housing 90. In one example, the heat conducting material may be a rubber and/or a foam based material. Such material may be in a paste or other form and may be applied to the front cover 92 with a pocket formed therein that may be configured to receive the thermistor 114.
Those skilled in the art will recognize that the present disclosure may be manifested in a variety of forms other than the specific embodiments described and contemplated herein. Accordingly, departure in form and detail may be made without departing from the scope and spirit of the present disclosure as described in the appended claims.
This application claims the benefit of U.S. Provisional Application Ser. No. 62/380,219, filed Aug. 26, 2016, the entirety of which is incorporated herein by reference.
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