AIR CONDITIONING APPLIANCE AND MAKE-UP AIR ASSEMBLY

A single-package air conditioner unit may include a housing, an outdoor heat exchanger assembly, an indoor heat exchanger assembly, an indoor heat exchanger, a compressor, and an intake conduit. The housing may define an outdoor portion and an indoor portion. The compressor may be in fluid communication with an outdoor heat exchanger and an indoor heat exchanger to circulate a refrigerant between the outdoor heat exchanger and the indoor heat exchanger. The intake conduit may extend from the housing. The intake conduit may define an intake passage upstream from the indoor heat exchanger assembly. The intake conduit may further define a primary inlet and a secondary inlet spaced apart from the primary inlet in fluid parallel thereto. The primary inlet and the secondary inlet may be defined upstream from the intake passage to separately permit air thereto.

FIELD OF THE INVENTION

The present subject matter relates generally to air conditioning appliances, and more particularly to assemblies for providing make-up air to air conditioning appliances.

BACKGROUND OF THE INVENTION

Air conditioner or air conditioning appliance units are conventionally used to adjust the temperature within structures such as dwellings and office buildings. In particular, one-unit type room air conditioner units, such as single-package vertical units (SPVU), may be used to adjust the temperature in, for example, a single room or group of rooms of a 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. Accordingly, the air conditioner unit generally extends through, for example, an outer wall of the structure. Generally, a fan may be operable to rotate to motivate air through the indoor portion. Another fan may be operable to rotate to motivate air through the outdoor portion. A sealed cooling system including a compressor is generally housed within the air conditioner unit to treat (e.g., cool or heat) air as it is circulated through the indoor portion of the air conditioner unit. One or more control boards are typically provided to direct the operation of various elements of the particular air conditioner unit.

Frequently, the indoor space may need to draw in air from the outdoors (i.e., make-up air). For example, if a vent fan is turned on in a bathroom or air is otherwise ejected from the indoor space, fresh air from the outdoors is required. Depending on, for example, the efficiency of the weather stripping around doors and windows, some make-up air could simply be drawn into the indoors by cracks or other openings. If such cracks are not sufficient, the flow of make-up air may be insufficient or too slow. Furthermore, government regulations, such as fire codes may require that cracks or openings be eliminated as much as possible—precluding a sufficient flow of make-up air. Accordingly, an air conditioner unit that can allow for the introduction of make-up air into the indoor space would be useful. Unfortunately, previous attempts to provide such make-up air have unsatisfactory. For example, previous systems ducting make-up air through a housing of the air conditioner unit may make it difficult to meet various government standards (e.g., related to heat management) or have difficulties maintaining various components (e.g., plastic components) within the housing.

As a result, it would be useful to provide an air conditioning appliance or door assembly that includes features for addressing one or more of the above issues. In particular, it may be advantageous to provide an appliance or assembly with features for supplying make-up air to an air conditioning unit.

BRIEF DESCRIPTION OF THE INVENTION

In one exemplary aspect of the present disclosure, a single-package air conditioner unit is provided. The single-package air conditioner unit may include a housing, an outdoor heat exchanger assembly, an indoor heat exchanger assembly, an indoor heat exchanger, a compressor, and an intake conduit. The housing may define an outdoor portion and an indoor portion. The outdoor heat exchanger assembly may be disposed in the outdoor portion and include an outdoor heat exchanger and an outdoor fan. The indoor heat exchanger assembly may be disposed in the indoor portion and comprising an indoor heat exchanger and an indoor fan. The compressor may be in fluid communication with the outdoor heat exchanger and the indoor heat exchanger to circulate a refrigerant between the outdoor heat exchanger and the indoor heat exchanger. The intake conduit may extend from the housing. The intake conduit may define an intake passage upstream from the indoor heat exchanger assembly. The intake conduit may further define a primary inlet and a secondary inlet spaced apart from the primary inlet in fluid parallel thereto. The primary inlet and the secondary inlet may be defined upstream from the intake passage to separately permit air thereto.

In another exemplary aspect of the present disclosure, a single-package air conditioner unit is provided. The single-package air conditioner unit may include a housing, an outdoor heat exchanger assembly, an indoor heat exchanger assembly, an indoor heat exchanger, a compressor, and an intake conduit. The housing may define an outdoor portion and an indoor portion. The outdoor heat exchanger assembly may be disposed in the outdoor portion and include an outdoor heat exchanger and an outdoor fan. The indoor heat exchanger assembly may be disposed in the indoor portion and comprising an indoor heat exchanger and an indoor fan. The compressor may be in fluid communication with the outdoor heat exchanger and the indoor heat exchanger to circulate a refrigerant between the outdoor heat exchanger and the indoor heat exchanger. The intake conduit may extend from the housing. The intake conduit may define an intake passage upstream from the indoor heat exchanger assembly. The intake conduit may further define a primary inlet and a secondary inlet spaced apart from the primary inlet in fluid parallel thereto. The primary inlet and the secondary inlet may be defined upstream from the intake passage to separately permit air thereto. The secondary inlet may have a minimum airflow cross-section that is less than a minimum airflow cross-section of the primary inlet. The primary inlet may be defined distal to the indoor heat exchange assembly. The secondary inlet may be defined proximal to the indoor heat exchange assembly.

DETAILED DESCRIPTION

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.

Turning now to the figures,FIGS. 1 through 3illustrate an exemplary air conditioner 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 package housing114supporting an indoor portion112and an outdoor portion110.

Generally, air conditioner100defines a vertical direction V, lateral direction L, and transverse direction T. Each direction V, L, T is perpendicular to each other, such that an orthogonal coordinate system is generally defined.

In some embodiments, housing114contains various other 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 embodiments, one or more components of outdoor portion110are mounted on a basepan136, 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 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 unit132. 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 basepan136(e.g., at a higher vertical position than outdoor heat exchanger120), as shown.

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 heating unit132) and returned to the indoor area of the 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 embodiments to direct air in any other suitable direction.

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, exemplary 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, exemplary 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 basepan136) and an expansion device (e.g., expansion valve or capillary tube—not pictured), 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 coils146,148, as illustrated, through which a refrigerant may flow for heat exchange purposes, as is generally understood.

A plenum166may be provided to direct air to or from housing114. When installed, plenum166may be selectively attached to (e.g., fixed to or mounted against) housing114(e.g., via a suitable mechanical fastener, adhesive, gasket, etc.) and extend through a structure wall150(e.g., an outer wall of the structure within which air conditioner100is installed). For instance, plenum166may extend (e.g., parallel to the transverse direction T) through a hole or channel152in the structure wall150that passes from an internal surface154to an external surface156.

As will be described in greater detail below, a make-up air assembly200may be provided to selectively direct outdoor or make-up air to the indoor portion112. Specifically, make-up air assembly200may direct outdoor air through the structure outer or wall150of the structure within which air conditioner100is installed (e.g., via plenum166) and to indoor heat exchanger122without first directing such outdoor or make-up air through housing114. To that end, make-up air assembly200may include one or more air ducts or conduits (e.g., intake conduit210or secondary air duct212) defining one or more air paths outside of housing114. During use, the flow of make-up air may thus be fluidly isolated from the flow of air through outdoor portion110.

The operation of air conditioner100including compressor126(and thus the sealed system generally), blower fan142, outdoor fan124, heating unit132, and other suitable components may be controlled by a control board or controller158. 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 panel160and one or more user inputs162, which may be included in control panel160. The user inputs162may be in communication with the controller158. A user of the air conditioner100may interact with the user inputs162to operate the air conditioner100, and user commands may be transmitted between the user inputs162and controller158to facilitate operation of the air conditioner100based on such user commands. A display164may additionally be provided in the control panel160, and may be in communication with the controller158. Display164may, 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.

Turning now especially toFIGS. 2 through 7, an exemplary make-up air assembly200will be described in greater detail.FIGS. 4 through 6, in particular, provide various views of make-up air assembly200(and portions thereof) in isolation (e.g., apart from housing114), whileFIG. 7provides a view of make-up air assembly200wherein a portion of secondary air duct212is removed for clarity (e.g., at a top portion of housing114).

As noted above, make-up air assembly200may be generally provided to selectively direct outdoor air to the indoor portion112. To that end, make-up air assembly200may include an intake conduit210that defines an intake passage214upstream from indoor inlet138. As shown, intake conduit210extends outward from housing114. For instance, intake passage214may extend along a passage axis X (e.g., horizontal or parallel to the transverse direction T), which the intake conduit210generally surrounds or radially bounds. In some such embodiments, intake passage214is parallel to passage axis X. When assembled, intake conduit210may be mounted to housing114, such as on an outer surface230of housing114. In turn, intake passage214may extend from a primary air inlet216(i.e., primary inlet), which is defined as an opening or aperture of intake conduit210, to indoor inlet138. Thus, primary air inlet216is spaced apart from indoor inlet138(e.g., along the transverse direction T). In some embodiments, primary air inlet216is coaxial with indoor inlet138. For instance, both primary air inlet216and indoor inlet138may be defined along the passage axis X. In turn, intake passage214may be a linear passage from primary air inlet216to indoor inlet138.

Generally, primary air inlet216defines an airflow cross section (e.g., minimum cross section) along a plane perpendicular to airflow through primary air inlet216. For instance, in the illustrated embodiments, the airflow cross section of primary air inlet216is defined by the dimensions of the height HP multiplied by the width WP.

Along with defining primary air inlet216, intake conduit210may define a secondary air inlet218(i.e., secondary inlet). In particular, secondary air inlet218may be defined separate from primary air inlet216. When assembled, secondary air inlet218may be spaced apart from primary air inlet216. For instance, secondary air inlet218may be defined in fluid parallel to primary air inlet216. Thus, airflow through secondary air inlet218to intake passage214may be distinct from airflow through primary air inlet216. Moreover, upstream from intake passage214, the airflows through secondary air inlet218and primary air inlet216may be independent from (i.e., not commingled with) each other.

In some embodiments, secondary air inlet218is defined along a non-parallel angle relative to primary air inlet216(i.e., such that primary air inlet216and secondary air inlet218are not defined along geometric parallel axes). For instance, secondary air inlet218may be defined through intake conduit210perpendicular to primary air inlet216(e.g., perpendicular to passage axis X). In optional embodiments, secondary air inlet218is defined above primary air inlet216. Thus, airflow through secondary air inlet218to intake passage214may flow downward. In additional or alternative embodiments, secondary air inlet218is closer to indoor inlet138(e.g., relative to the passage axis X) than primary air inlet216. Thus, secondary air inlet218may be proximal to indoor inlet138while primary air inlet216is distal to indoor inlet138.

Generally, secondary air inlet218defines an airflow cross section (e.g., minimum cross section) along a plane perpendicular to airflow through secondary air inlet218. For instance, in the illustrated embodiments, the airflow cross section of secondary air inlet218is defined by the dimensions of the length HS multiplied by the width WS. In certain embodiments, such as those illustrated inFIGS. 2 through 7, the airflow cross section of secondary air inlet218is less than the airflow cross section of primary air inlet216.

As shown, especially inFIGS. 2 through 4 and 6, a filter panel220may be disposed (e.g., selectively or removably disposed) on intake conduit210. In particular, filter panel220may be disposed in fluid communication with intake passage214to filter air thereto. For instance, filter panel220may be in fluid communication with primary air inlet216while being spaced apart from secondary air inlet218. During use, airflow to intake passage214through primary air inlet216may thus be forced through filter panel220in order to flow to intake passage214. By contrast, airflow to intake passage214through secondary air inlet218may advantageously bypass filter panel220altogether. Optionally, indoor inlet138may be unobstructed by any filtration media, ensuring a direct flow path from intake passage214to the indoor portion112. Notably, bypassing filter panel220may prevent significant resistance to make-up air (e.g., while ensuring filtration of most of the airflow, such as the non-makeup airflow to indoor inlet138).

In some embodiments, filter panel220is disposed in front primary air inlet216(e.g., along the transverse direction T or otherwise outside from intake passage214). Moreover, filter panel220may be upstream from primary air inlet216. One or more mounting brackets222may be provided to hold filter panel220on intake conduit210. For instance, as illustrated, a pair of mounting brackets222that each defining a discrete support channel to slidably receive filter panel220may be provided on opposite ends (e.g., opposite lateral ends or vertical ends) of intake conduit210or primary air inlet216. As shown, each mounting bracket222may be opened at one end (e.g., a top end) while being closed at an opposite end (e.g., a bottom end) to support filter panel220or otherwise prevent filter panel220from sliding directly through (i.e., out of) the mounting brackets222during installation of filter panel220on intake conduit210. Filter panel220itself may be provided as any suitable frame or structure including a suitable air filtration media (e.g., cellulose, fiberglass, foam, etc.).

In some embodiments, a secondary air duct212is mounted or attached to intake conduit210to direct outdoor (i.e., make-up) air to secondary air inlet218. Thus, secondary air duct212may be disposed upstream from secondary air inlet218to direct air thereto. Moreover, secondary air duct212may define a secondary passage224that extends from an outdoor end226to an indoor end228. In certain embodiments, outdoor end226is positioned at or proximal to plenum166while indoor end228is positioned at or proximal to secondary air inlet218, as shown.

When assembled, secondary air duct212may extend from intake conduit210outside of housing114. Thus, secondary passage224may be defined outside of housing114apart from indoor portion112and outdoor portion110. In certain embodiments, secondary air duct212is disposed on outer surface230of housing114. Thus, while secondary air duct212is separate from housing114, secondary air duct212may be held to housing114(e.g., as a single unit) without commingling air through outdoor portion110and secondary passage224, or without motivating air within housing114across an exterior surface of secondary air duct212(e.g., opposite from the interior secondary passage224). Optionally, an insulation layer238(e.g., insulating foam, sheet, or panels) may be disposed on the exterior surface of secondary air duct212outside of housing114.

Outdoor end226of secondary air duct212defines a duct intake232through which outdoor or make-up air may enter secondary passage224. In certain embodiments, duct intake232may be disposed directly above the outdoor outlet130(e.g., at the plenum166). In order to direct air from an outdoor region to intake conduit210, duct intake232is generally offset or spaced apart from secondary air inlet218in or along at least one direction (e.g., the transverse direction T). As shown, duct intake232may further be offset from secondary air inlet218in a second direction (e.g., in the vertical direction V or lateral direction L). In the illustrated embodiments, indoor end228(and thus secondary air inlet218) is both horizontally and vertically offset from duct intake232. For instance, secondary air inlet218may be transversely offset and lower than the duct intake232. Airflow through secondary passage224may thus be drawn forward and downward, notably maintaining a compact assembly while minimizing the resistance of airflow through secondary passage224.

In some embodiments, one or more movable airflow elements may be disposed or mounted within secondary air duct212to selectively motivate or restrict airflow through secondary passage224. As an example, a make-up fan234(e.g., axial fan, tangential fan, etc.) may be mounted within secondary air duct212to selectively direct air therethrough. In some such embodiments, controller158is in operable (e.g., electric or wireless) communication with make-up fan234. During operation, controller158may thus selectively activate or initiate rotation of make-up fan234to motivate make-up air to intake conduit210. As an additional or alternative example, a damper door236may be movably mounted in the secondary air duct212to selectively permit air therethrough. In some such embodiments, controller158is in operable (e.g., electric or wireless) communication with damper door236(e.g., a motor thereof). During operation, controller158may thus selectively activate or initiate movement of damper door236to an open position to permit motivate make-up air to intake conduit210. Moreover, controller158may separately activate or initiate movement of damper door236to a closed position to restrict airflow through secondary air duct212(e.g., when make-up air is not desired).

Advantageously, the above-described embodiments of make-up air assembly200may provide or permit efficient make-up airflow (e.g., without create a risk of damage to components within the housing114).