Patent Application
20200393143
The present disclosure relates generally to air conditioner units, and more particularly to packaged terminal air conditioner units and features for regulating make-up air.
Air conditioner or conditioning units are conventionally utilized to adjust the temperature indoors—i.e. within structures such as dwellings and office buildings. Such units commonly include a closed refrigeration loop to heat or cool the indoor air. Typically, the indoor air is recirculated while being heated or cooled. A variety of sizes and configurations are available for such air conditioner units. For example, some units may have one portion installed within the indoors that is connected, by e.g., tubing carrying the refrigerant, to another portion located outdoors. These types of units are typically used for conditioning the air in larger spaces.
Another type of unit, sometimes referred to as a packaged terminal air conditioner unit (PTAC), may be used for somewhat smaller indoor spaces that are to be air conditioned. These units may include both an indoor portion and an outdoor portion separated by a bulkhead and may be installed in windows or positioned within an opening of an exterior wall of a building. PTACs often need to draw air from the outdoor portion into the indoor portion. For example, if a bathroom fan is turned on or air is otherwise ejected from the indoor space, fresh air may be required to supplement or make-up for the lost air.
Accordingly, certain PTACs allow for the introduction of make-up air into the indoor space, e.g., through a vent aperture defined in the bulkhead that separates the indoor and outdoor side of the unit. The vent aperture is usually equipped with an auxiliary fan and/or make-up air module to urge a flow of make-up air from the outdoor side of the PTAC into the conditioned room. In addition, a motorized vent door is pivotally mounted over the vent aperture to control the flow of make-up air.
However, in certain situations, pressure variation within the room may affect the flow rate of make-up air through the vent aperture. For example, if the auxiliary fan is urging air through the vent aperture at a target flow rate when a pressure reduction is generated in the room, e.g., such as when a bathroom fan is turned on, the actual flow rate may exceed the target flow rate.
Accordingly, improved air conditioner units and features for achieving the target make-up flow rate would be useful. More specifically, packaged terminal air conditioner units and make-up air modules that facilitate improved control of make-up air flow rates would be particularly beneficial.
Aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.
In accordance with one embodiment, an air conditioner unit is provided. The air conditioner unit includes a bulkhead defining an indoor portion and an outdoor portion, a vent aperture defined in the bulkhead, and an auxiliary fan positioned proximate the vent aperture and being configured for urging a flow of make-up air from the outdoor portion through the vent aperture to the indoor portion. A vent door is positioned proximate the vent aperture, the vent door being pivotable between an open position for allowing the flow of make-up air through the vent aperture and a closed position for blocking the flow of make-up air through the vent aperture. A flow restrictor extends into the flow of make-up air, the flow restrictor being movable in correlation to a flow rate of the flow of make-up air.
In accordance with another embodiment, an air conditioner unit is provided including a bulkhead including a door frame defining a vent aperture. A vent door is mounted to the door frame over the vent aperture, the vent door being pivotable to regulate a flow of make-up air through the vent aperture. A flow restrictor extends into the flow of make-up air, the flow restrictor being movable to regulate a flow area defined between the door frame, the vent door, and the flow restrictor.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
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.
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.
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 or spirit 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.
As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “upstream” and “downstream” refer to the relative direction with respect to fluid flow in a fluid pathway. For example, “upstream” refers to the direction from which the fluid flows and “downstream” refers to the direction to which the fluid flows. In addition, terms of approximation, such as “approximately,” “substantially,” or “about,” refer to being within a ten percent margin of error.
Referring now to
A housing 20 of the unit 10 may contain various other components of the unit 10. Housing 20 may include, for example, a rear grill 22 and a room front 24 which may be spaced apart along the transverse direction T by a wall sleeve 26. The rear grill 22 may be part of the outdoor portion 14, and the room front 24 may be part of the indoor portion 12. Components of the outdoor portion 14, such as an outdoor heat exchanger 30, an outdoor fan 32 (
Referring now also to
Outdoor and indoor heat exchangers 30, 40 may be components of a refrigeration loop 48, which is shown schematically in
As is understood in the art, refrigeration loop 48 may be alternately be operated as a refrigeration assembly (and thus perform a refrigeration cycle) or a heat pump (and thus perform a heat pump cycle). As shown in
According to an example embodiment of the present subject matter, compressor 34 is a single speed compressor configured for operating at a desirable rated operating speed. However, it should be appreciated that according to alternative embodiments, compressor 34 may be a variable speed compressor. In this regard, compressor 34 may be operated at various speeds depending on the current air conditioning needs of the room and the demand from refrigeration loop 48. For example, according to an exemplary embodiment, compressor 34 may be configured to operate at any speed between a minimum speed, e.g., 1500 revolutions per minute (RPM), to a maximum rated speed, e.g., 3500 RPM. Notably, use of variable speed compressor 34 enables efficient operation of refrigeration loop 48 (and thus air conditioner unit 10), minimizes unnecessary noise when compressor 34 does not need to operate at full speed, and ensures a comfortable environment within the room.
In exemplary embodiments as illustrated, expansion device 50 may be disposed in the outdoor portion 14 between the indoor heat exchanger 40 and the outdoor heat exchanger 30. According to the exemplary embodiment, expansion device 50 may be a capillary tube or another suitable expansion device configured for use in a thermodynamic cycle. However, according to alternative embodiments, expansion device may be an electronic expansion valve that enables controlled expansion of refrigerant, as is known in the art. In this regard, electronic expansion device 50 may be configured to precisely control the expansion of the refrigerant to maintain, for example, a desired temperature differential of the refrigerant across the indoor heat exchanger 40. In other words, electronic expansion device 50 throttles the flow of refrigerant based on the reaction of the temperature differential across indoor heat exchanger 40 or the amount of superheat temperature differential, thereby ensuring that the refrigerant is in the gaseous state entering compressor 34.
According to the illustrated exemplary embodiment, outdoor fan 32 is an axial fan and indoor blower fan 42 is a centrifugal fan. However, it should be appreciated that according to alternative embodiments, outdoor fan 32 and blower fan 42 may be any suitable fan type. In addition, according to an exemplary embodiment, outdoor fan 32 and blower fan 42 are variable speed fans. For example, outdoor fan 32 and blower fan 42 may rotate at different rotational speeds, thereby generating different air flow rates. It may be desirable to operate fans 32, 42 at less than their maximum rated speed to ensure safe and proper operation of refrigeration loop 48 at less than its maximum rated speed, e.g., to reduce noise when full speed operation is not needed. In addition, according to alternative embodiments, fans 32, 42 may be operated to urge make-up air into the room.
According to the illustrated embodiment, blower fan 42 may operate as an evaporator fan in refrigeration loop 48 to encourage the flow of air through indoor heat exchanger 40. Accordingly, blower fan 42 may be positioned downstream of indoor heat exchanger 40 along the flow direction of indoor air and downstream of heating unit 44. Alternatively, blower fan 42 may be positioned upstream of indoor heat exchanger 40 along the flow direction of indoor air, and may operate to push air through indoor heat exchanger 40.
Heating unit 44 in exemplary embodiments includes one or more heater banks 60. Each heater bank 60 may be operated as desired to produce heat. In some embodiments as shown, three heater banks 60 may be utilized. Alternatively, however, any suitable number of heater banks 60 may be utilized. Each heater bank 60 may further include at least one heater coil or coil pass 62, such as in exemplary embodiments two heater coils or coil passes 62. Alternatively, other suitable heating elements may be utilized.
The operation of air conditioner unit 10 including compressor 34 (and thus refrigeration loop 48 generally) blower fan 42, outdoor fan 32, heating unit 44, expansion device 50, and other components of refrigeration loop 48 may be controlled by a processing device such as a controller 64. Controller 64 may be in communication (via for example a suitable wired or wireless connection) to such components of the air conditioner unit 10. Controller 64 may include a 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 unit 10. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor.
Unit 10 may additionally include a control panel 66 and one or more user inputs 68, which may be included in control panel 66. The user inputs 68 may be in communication with the controller 64. A user of the unit 10 may interact with the user inputs 68 to operate the unit 10, and user commands may be transmitted between the user inputs 68 and controller 64 to facilitate operation of the unit 10 based on such user commands. A display 70 may additionally be provided in the control panel 66, and may be in communication with the controller 64. Display 70 may, for example be a touchscreen or other text-readable display screen, or alternatively may simply be a light that can be activated and deactivated as required to provide an indication of, for example, an event or setting for the unit 10.
Referring briefly to
As shown in
In some cases, it may be desirable to treat or condition make-up air flowing through vent aperture 80 prior to blowing it into the room. For example, outdoor air which has a relatively high humidity level may require treating before passing into the room. In addition, if the outdoor air is cool, it may be desirable to heat the air before blowing it into the room. Therefore, as illustrated in
As illustrated, make-up air module 90 includes auxiliary fan 92 that is configured as part of auxiliary sealed system 90 and may be configured for urging a flow of air (indicated herein by reference numeral 94) through auxiliary sealed system 90. Auxiliary sealed system 90 may further includes one or more compressors, heat exchangers, and any other components suitable for operating auxiliary sealed system 90 similar to refrigeration loop 48 described above to condition make-up air. For example, auxiliary system 90 can be operated in a dehumidification mode, an air conditioning mode, a heating mode, a fan only mode where only auxiliary fan 92 is operated to supply outdoor air, an idle mode, etc.
Referring now generally to
Referring now specifically to
According to an exemplary embodiment, the magnitude of pivoting, deflection, or movement of flow restrictor 100 is “correlated” to the makeup air flow rate. In this regard, for example, the movement of the flow restrictor 100 may be directly or indirectly related to the makeup air flow rate. According to one exemplary embodiment, the deflection and/or flow restriction are directly proportional to the makeup air flow rate. In this regard, for example, the deflection of flow restrictor 100, and thus restriction of the flow area, is proportional to the make-up air flow rate. According to other embodiments, the movement of flow restrictor 100 is nonlinearly related to the makeup air flow rate. Although exemplary relationships are described herein, it should be appreciated that the precise configuration and movement of flow restrictor 100 in response to various flow rates may vary while remaining within scope of the present subject matter.
As shown, door frame 78, vent door 82, and flow restrictor 100 may generally define a flow passageway 102 which extends from outdoor portion 14, through vent aperture 80, and into indoor portion 12. The most narrow and restricting portion of flow passageway 102 may be defined between flow restrictor 100 and vent door 82. The term “flow area” may be used herein to refer to the cross sectional flow area of flow passageway 102 at this most restricted portion between flow restrictor 100 and vent door 82. According to exemplary embodiments, flow restrictor 100 is configured for moving to adjust the flow area of flow passageway 102 to achieve desired makeup air flow rates.
For example, flow restrictor 100 may move to restrict flow passageway 102 more at higher flow rates than at lower flow rates. Thus, for example, if the pressure difference across vent aperture 80 would cause the flow of makeup air 94 to pass through vent aperture 80 at first, lower flow rate, e.g., 30 cubic feet per minute (CFM) in the absence of flow restrictor 100, flow restrictor 100 may remain substantially in the retracted state. In this manner, flow passageway 102 is substantially unrestricted such that the actual flow rate remains around 30 CFM. By contrast, if the pressure difference were substantially higher, such that the makeup air flow rate would be 80 CFM in the absence of flow restrictor 100, flow restrictor 100 may be deflected to restrict flow passageway 102 and limit the makeup air flow rate to a lower amount.
According to an exemplary embodiment, flow restrictor 100 may be configured for limiting the makeup air flow rate below a threshold flow rate, e.g., a maximum target flow rate. According to an exemplary embodiment, the target flow rate may be about 37 CFM. According to an exemplary embodiment, flow restrictor 100 may be configured for deflecting to prevent the flow rate from passing the target flow rate or threshold regardless of the pressure difference created across flow aperture 80. According still other embodiments, flow restrictor 100 may be configured for closing altogether in the event flow rates would exceed a high flow threshold in the absence of flow restrictor 100.
Although exemplary values are described herein for the flow rates, it should be appreciated that system configurations may vary these flow rates while remaining within the scope of the present subject matter. Thus, the size and orientation of vent aperture 80, flow passageway 102, and flow restrictor 100 may be adjusted to manipulate the makeup air flow rates, while desirable target thresholds and max flowrates may also be adjusted according to exemplary embodiments. In addition, further restricting features may be defined within flow passageway 102 according to alternative embodiments.
As illustrated in
According to the illustrated embodiment, flap 112 is a thin rectangular member that is substantially rigid. For example, flap 112 may be formed from a rigid plastic or a piece of sheet metal. According to such an embodiment, the flexibility or mobility of flow restrictor 100 is introduced via resilient element 110. However, it should be appreciated that according to alternative embodiments, resilient element 110 and flap 112 may be a single element with sufficient flexibility to achieve the same purpose. In this regard, alternative embodiments could use a single piece of spring steel or other pliable material formed to have a suitable shape and resiliency to deflect into flow passageway 102 under the force of the flow of makeup air 94 and spring back to the retracted position under relatively low flow rates.
According to the specific embodiment illustrated in
During operation of PTAC 10 and makeup air module 90, the flow of makeup air 94 may pass through the aperture 80 at various flowrates. If the makeup air flow rate is relatively low, resilient element 110 will maintain flap 112 in a retracted position (e.g., as shown in
Referring now to
As shown, flap 112 is pivotally mounted to a bottom end 130 of vent door 82 and extends upstream into flow of makeup air 94. In addition, resilient element 110 is a mechanical coil spring 132 extending between vent door 82 and flap 112. More specifically, mechanical coil spring 132 is mounted to a distal end 134 of flap 112 for urging flap 112 toward a retracted position (e.g., as shown in
According to an exemplary embodiment of the present subject matter, flow restrictor 100 may further include a mechanical stop 140 which is generally configured for stopping the deflection of flow restrictor 100 at a certain desirable position or angle. In this regard, as illustrated for example in
As explained herein, the sizes and shapes of vent aperture 80, flow passageway 102, and flow restrictor 100 may vary to adjust the flowrates through flow passageway 102. For example, according to an exemplary embodiment, vent aperture defines an aperture height 150 measured along the vertical direction V and flow restrictor 100 defines a restrictor height 152. According to an exemplary embodiment, restrictor height 152 may be greater than 10%, greater than 20%, greater than 40%, or greater than 50% of aperture height 150. In addition, restrictor height 152 may be less than 90%, less than 60%, less than 40%, or less than 10% of aperture height 150. Other restrictor heights 152 are possible and within scope of the present subject matter.
In addition, according to an exemplary embodiment, vent aperture 80 may define an aperture width 154 (see, e.g.,
Referring now to
As illustrated in the various embodiments from
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.
