SYSTEMS AND METHODS FOR LIMITING AIR CONDITIONER DISCHARGE RATE

An air conditioning appliance includes a housing with a heat exchanger. A compressor is in fluid communication with the heat exchanger. The compressor is operable to circulate refrigerant through the heat exchanger. A fan is disposed within the housing. The fan is operable to flow air over the heat exchanger. A temperature sensor is disposed at an indoor portion of the housing. The controller is configured to receive a signal from the temperature sensor corresponding to a temperature measurement, and to compare the temperature measurement to a set temperature. The controller is configured to operate the fan at a first operating speed until a temperature condition is met. The controller is also configured to operate the fan at a second operating speed when the temperature condition is met.

FIELD OF THE INVENTION

The present subject matter relates generally to systems and methods for limiting the discharge rate of air conditioners.

BACKGROUND OF THE INVENTION

Air conditioners or air conditioner units are conventionally used to adjust the temperature within structures, such as dwellings and office buildings. One-unit type room air conditioners, such as single package vertical units (SPVU) or package terminal air conditioners (PTAC), are frequently used to adjust the temperature in a single room or group of rooms of a structure. Such units may be especially useful in the context of a hotel or office building where users desire control of the temperature within a specific room of a larger building structure. A typical one-unit type air conditioner or air conditioning appliance includes an indoor portion and an outdoor portion. The indoor portion generally communicates (e.g., exchanges air) with the area within a building, and the outdoor portion generally communicates (e.g., exchanges air) with the area outside a building. Generally, a fan may be operable to rotate to motivate air through the indoor portion, and another fan may be operable to rotate to motivate air through the outdoor portion. One or more control boards are typically provided to direct the operation of various elements of the particular air conditioner unit.

BRIEF DESCRIPTION OF THE INVENTION

In one example embodiment, an air conditioning appliance includes a housing with a heat exchanger disposed within the housing. A compressor is in fluid communication with the heat exchanger. The compressor is operable to circulate refrigerant through the heat exchanger. A fan is disposed within the housing. The fan is operable to flow air over the heat exchanger. A temperature sensor is disposed at an indoor portion of the housing. A controller is in operative communication with the temperature sensor. The controller is configured to receive a signal from the temperature sensor corresponding to a temperature measurement, and to compare the temperature measurement to a set temperature. The controller is configured to operate the fan at a first operating speed until a temperature condition is met. The controller is also configured to operate the fan at a second operating speed when the temperature condition is met. The second operating speed is greater than the first operating speed.

In another example embodiment, a method of operating an air conditioning appliance includes adjusting, at a controller, an operating speed of a fan to a first operating speed. Then receiving, at the controller, a temperature measurement. Determining, at the controller, satisfaction of a temperature condition based at least in part on a difference between the temperature measurement and a set temperature. Then adjusting, at the controller, the operating speed of the fan to a second operating speed in response to the satisfaction of the temperature condition.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). The terms “upstream” and “downstream” refer to the relative flow direction with respect to fluid flow in a fluid pathway. For example, “upstream” refers to the flow direction from which the fluid flows, and “downstream” refers to the flow direction to which the fluid flows. Furthermore, as used herein, terms of approximation, such as “approximately,” “substantially,” or “about,” refer to being within a ten percent margin of error.

Turning now to the figures,FIGS.1through3illustrate an example air conditioning appliance (e.g., air conditioner100). As shown, air conditioner100may be provided as a one-unit type air conditioner100, such as a single-package vertical unit. Air conditioner100includes a housing114supporting an indoor portion112and an outdoor portion110. Generally, air conditioner100defines a vertical direction V, lateral direction L, and transverse direction T that are mutually perpendicular, e.g., such that an orthogonal coordinate system is generally defined.

In some example embodiments, housing114contains various components of the air conditioner100. Housing114may include, for example, a rear opening116(e.g., with or without a grill or grate thereacross) and a front opening118(e.g., with or without a grill or grate thereacross) may be spaced apart from each other along the transverse direction T. The rear opening116may be part of the outdoor portion110, while the front opening118is part of the indoor portion112. Components of the outdoor portion110, such as an outdoor heat exchanger120, outdoor fan124, and compressor126may be enclosed within housing114between front opening118and rear opening116. In certain example embodiments, one or more components of outdoor portion110are mounted on a base pan136, as shown.

During certain operations, air may be drawn to outdoor portion110through rear opening116. Specifically, an outdoor inlet128defined through housing114may receive outdoor air motivated by outdoor fan124. Within housing114, the received outdoor air may be motivated through or across outdoor fan124. Moreover, at least a portion of the outdoor air may be motivated through or across outdoor heat exchanger120before exiting the rear opening116at an outdoor outlet130. It is noted that although outdoor inlet128is illustrated as being defined above outdoor outlet130, alternative example embodiments may reverse this relative orientation (e.g., such that outdoor inlet128is defined below outdoor outlet130) or provide outdoor inlet128beside outdoor outlet130in a side-by-side orientation, or another suitable discrete orientation.

As shown, indoor portion112may include an indoor heat exchanger122, a blower fan142, and a heating unit (not shown). These components may, for example, be housed behind the front opening118. A bulkhead134may generally support or house various other components or portions thereof of the indoor portion112, such as the blower fan142. Bulkhead134may generally separate and define the indoor portion112and outdoor portion110within housing114. Additionally, or alternatively, bulkhead134or indoor heat exchanger122may be mounted on base pan136(e.g., at a higher vertical position than outdoor heat exchanger120).

During certain operations, air may be drawn to indoor portion112through front opening118. Specifically, an indoor inlet138defined through housing114may receive indoor air motivated by blower fan142. At least a portion of the indoor air may be motivated through or across indoor heat exchanger122(e.g., before passing to bulkhead134). From blower fan142, indoor air may be motivated (e.g., across the heating unit, which may include one or more electric or resistive heating elements) and returned to an indoor area of a room through an indoor outlet140defined through housing114(e.g., above indoor inlet138along the vertical direction V). Optionally, one or more conduits (not pictured) may be mounted on or downstream from indoor outlet140to further guide air from air conditioner100. It is noted that although indoor outlet140is illustrated as generally directing air upward, it is understood that indoor outlet140may be defined in alternative example embodiments to direct air in any other suitable direction. A temperature sensor200may be mounted in indoor outlet140to measure the temperature of the air inside indoor outlet140. Additional temperature sensors may be used, i.e., on heat exchanger122, or on the exterior of air conditioner100. The exterior temperature sensor (not shown) may measure an ambient indoor air temperature.

Outdoor and indoor heat exchanger120,122may be components of a thermodynamic assembly (i.e., sealed system), which may be operated as a refrigeration assembly (and thus perform a refrigeration cycle) or, in the case of the heat pump unit embodiment, a heat pump (and thus perform a heat pump cycle). Thus, as is understood, example heat pump unit embodiments may be selectively operated perform a refrigeration cycle at certain instances (e.g., while in a cooling mode) and a heat pump cycle at other instances (e.g., while in a heating mode). By contrast, example A/C exclusive unit embodiments may be unable to perform a heat pump cycle (e.g., while in the heating mode), but still perform a refrigeration cycle (e.g., while in a cooling mode).

The sealed system may, for example, further include compressor126(e.g., mounted on base pan136) and an expansion device (e.g., expansion valve or capillary tube—not shown), both of which may be in fluid communication with the heat exchangers120,122to flow refrigerant therethrough, as is generally understood. The outdoor and indoor heat exchanger120,122may each include coils, as illustrated, through which a refrigerant may flow for heat exchange purposes, as is generally understood.

The operation of air conditioner100including compressor126(and thus the sealed system generally), blower fan142, outdoor fan124, the heating unit, and other suitable components may be controlled by a control board or controller158(FIG.3). Controller158may be in communication (via for example a suitable wired or wireless connection) to such components of the air conditioner100. By way of example, the controller158may 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 air conditioner100. The memory may be a separate component from the processor or may be included onboard within the processor. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH.

Air conditioner100may additionally include a control panel and one or more user inputs, which may be included in control panel. The user inputs may be in communication with the controller158. A user of the air conditioner100may interact with the user inputs to operate the air conditioner100, and user commands may be transmitted between the user inputs and controller158to facilitate operation of the air conditioner100based on such user commands. A display may additionally be provided in the control panel and may be in communication with the controller158. The display 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 air conditioner100.

FIG.4illustrates a method400for operating an air conditioning appliance, such as air conditioner100ofFIGS.1through3. Method400may begin at410when air conditioner100begins either the heat pump cycle or refrigeration cycle. At420, controller158may adjust blower fan142to a first operating speed. The first operating speed of blower fan142may be equivalent to a “low” fan setting. The first operating speed of blower fan142may be greater than zero such that the blower fan142flows air. Controller158may operate blower fan142at the first operating speed until, at430, a temperature condition is satisfied. At430, there may be numerous temperature conditions that may be satisfied. For example, the present example embodiment includes eight conditions,431through438. In each condition431through438, the temperature measurement may be above or below the set temperature by an offset amount, about plus or minus three degrees Celsius (3° C.).

Condition431may be satisfied when the temperature measurement from temperature sensor200is above or below the ambient indoor air temperature, depending on the type of cycle air conditioner100is performing. Condition432may be satisfied when the temperature measurement of the heat exchanger temperature is above or below the temperature measurement of the ambient indoor air temperature. Condition433may be satisfied when an integration of the temperature measurement from temperature sensor200above or below the ambient indoor air temperature with respect to time exceeds a threshold value (° C.-second). The threshold value may be a value or a plurality of values stored on controller158. The threshold value may also be a calculation of the integral of the set temperature with respect to time. Condition434may be satisfied when an integration of the heat exchanger temperature above or below the ambient indoor air temperature with respect to time is above or below the threshold value. For example, condition433may be satisfied if the integration of temperature measurement above the ambient indoor air temperature with respect to time exceeds a threshold value (° C.-second).

At439, four of the conditions,435through438, may be governed by a set period of time. The time may be between ten seconds (10 sec) and ten minutes (10 min). Condition435may be satisfied when the temperature measurement from temperature sensor200is above or below the ambient indoor air temperature by the offset amount for the set period of time. The set period of time may correlate to a number of samples, i.e., temperature measurements, taken during the period of time. Condition436may be satisfied when the temperature measurement of the heat exchanger temperature is above or below the temperature measurement of the ambient indoor air temperature by the offset amount for the set period of time. Condition437may be satisfied when the integration of the temperature measurement above or below the temperature of the ambient indoor air temperature with respect to time exceeds the threshold value for the set period of time. Condition438may be satisfied when the integration of the heat exchanger temperature above or below the ambient indoor air temperature with respect to time exceeds the threshold value for the set period of time. For example, condition437may be satisfied if the integration of temperature measurement above the ambient indoor air temperature with respect to time exceeds a threshold value (° C.-second) for the duration of the set period of time.

When at least one of condition431through438is satisfied, the method400may proceed to440. At440, controller158may adjust blower fan142to a second operating speed. The second operating speed of blower fan142may be equivalent to a “normal” setting. The second operating speed may at least be greater than the first operating speed of blower fan142. As an example, the second operating speed may be no less than twenty percent (20%) greater, no less than fifty percent (50%) greater, no less than seventy-five percent (75%) greater, no less than one hundred percent (100%) greater, no less than two hundred percent (200%) greater, no less than five hundred percent (500%) greater, etc. Accordingly, method400may start either the heat pump cycle or refrigeration cycle, with blower fan142operating at a slower speed than normal. Blower fan142may remain at the slow speed until a temperature condition is met. Once the temperature condition is met, blower fan142may operate at a speed that is faster than the slow speed or considered the normal speed. One skilled in the art would understand that method400may be applied to any air conditioner appliance, and air conditioner100is provided by way of example and is not intended to be limiting.

As may be seen above, when air conditioner100enters a cooling or heating cycle, controller158may operate the blower fan142at the first, slower, low speed. The controller then monitors the indoor ambient temperature and temperature inside of air conditioner100, waiting for a temperature condition to be met. Blower fan142may remain at the slow speed until at least one of the temperature conditions is met. Once the temperature condition is met controller158may adjust blower fan142to a second, faster, normal speed.