Patent Publication Number: US-10775055-B2

Title: Bulkhead assemblies for air conditioner units

Description:
FIELD OF THE INVENTION 
     The present disclosure relates generally to air conditioner units, and more particularly to improved apparatus for accessing connectors associated with bulkheads of air conditioner units. 
     BACKGROUND OF THE INVENTION 
     Air conditioner units are conventionally utilized to adjust the temperature within structures such as dwellings and office buildings. In particular, one-unit type room air conditioner units may be utilized to adjust the temperature in, for example, a single room or group of rooms of a structure. A typical such air conditioner unit includes an indoor portion and an outdoor portion. The indoor portion is generally located indoors, and the outdoor portion is generally located outdoors. Accordingly, the air conditioner unit generally extends through a wall, window, etc. of the structure. 
     In the outdoor portion of a conventional air conditioner unit, a compressor that operates a refrigerating cycle is provided. At the back of the outdoor portion, an outdoor heat exchanger connected to the compressor is disposed, and facing the outdoor heat exchanger, an outdoor fan for cooling the outdoor heat exchanger is provided. At the front of the indoor portion of a conventional air conditioner unit, an air inlet is provided, and above the air inlet, an air outlet is provided. A blower fan and a heating unit are additionally provided in the indoor portion. Between the blower fan and heating unit and the air inlet, an indoor heat exchanger connected to the compressor is provided. 
     When cooling operation starts, the compressor is driven to operate the refrigerating cycle, with the indoor heat exchanger serving as a cold-side evaporator of the refrigerating cycle, and the outdoor heat exchanger as a hot-side condenser. The outdoor heat exchanger is cooled by the outdoor fan to dissipate heat. As the blower fan is driven, the air inside the room flows through the air inlet into the air passage, and the air has its temperature lowered by heat exchange with the indoor heat exchanger, and is then blown into the room through the air outlet. In this way, the room is cooled. 
     When heating operation starts, the heating unit is operated to raise the temperature of air in the air passage. The air, having had its temperature raised, is blown out through the air outlet into the room to heat the room. 
     Further, conventional air conditioner units include a bulkhead which is positioned between the indoor portion and outdoor portion, and thus generally separates the components within the indoor portion from the components in the outdoor portion. Various components may additionally be connected to the bulkhead, such as the blower fan and heating unit. Components which may be connected to the bulkhead include components located in both the indoor portion and the outdoor portion of the air conditioner unit. 
     One issue with many presently known bulkheads and air conditioner units is the difficulty in accessing connectors positioned on only one side of the bulkhead. 
     Accordingly, improved apparatus for accessing connectors associated with bulkheads in air conditioner units is desired in the art. In particular, apparatus which facilitate such access during manufacture and/or maintenance of air conditioner units and thus reducing the associated time and labor would be advantageous. 
     BRIEF DESCRIPTION OF THE INVENTION 
     Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious 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 defines a vertical direction, a lateral direction, and a transverse direction. The vertical direction, the lateral direction, and the transverse directions are mutually perpendicular. The air conditioner unit includes at least one outdoor component disposed in an outdoor portion of the air conditioner unit and at least one indoor component disposed in an indoor portion of the air conditioner unit. A bulkhead is disposed between the outdoor portion and the indoor portion along the transverse direction. The bulkhead includes an indoor surface facing the indoor portion of the air conditioner unit and an outdoor surface facing the outdoor portion of the air conditioner unit. At least one indoor connector is disposed on the bulkhead and faces the indoor portion of the air conditioner unit. At least one outdoor connector is disposed on the bulkhead and faces the outdoor portion of the air conditioner unit. 
     In accordance with another embodiment, a bulkhead assembly of an air conditioner unit is provided. The bulkhead assembly is disposed between an indoor portion of an air conditioner unit and an outdoor portion of the air conditioner unit. The bulkhead assembly includes a bulkhead which includes a first surface facing a first direction and a second surface facing a second direction. The second surface is opposite the first surface. A first connector is disposed on the bulkhead facing the first direction. A second connector is disposed on the bulkhead facing the second direction. 
     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. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       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. 
         FIG. 1  provides an exploded perspective view of an exemplary air conditioner unit which may incorporate a bulkhead assembly in accordance with one or more embodiments of the present disclosure. 
         FIG. 2  is a perspective view of an indoor side of a bulkhead assembly in accordance with one or more embodiments of the present disclosure. 
         FIG. 3  is a perspective view of an outdoor side of the bulkhead assembly of  FIG. 2 . 
         FIG. 4  is an enlarged view of a portion of  FIG. 2 . 
         FIG. 5  is an enlarged view of a portion of  FIG. 3 . 
     
    
    
     DETAILED DESCRIPTION OF THE 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, terms of approximation, such as “generally,” or “about” include values within ten percent greater or less than the stated value. When used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction. For example, “generally vertical” includes directions within ten degrees of vertical in any direction, e.g., clockwise or counter-clockwise. 
     Referring now to  FIG. 1 , an exemplary air conditioner unit  100  is illustrated. The air conditioner unit  100  is a one-unit type air conditioner, also conventionally referred to as a room air conditioner. The unit  100  includes an indoor portion  130  and an outdoor portion  150 , and generally defines a vertical direction V, a lateral direction L, and a transverse direction T. The vertical direction V, the lateral direction L, and the transverse direction T are mutually perpendicular to each other, such that an orthogonal coordinate system is generally defined. 
     Air conditioner unit  100  is operable to generate chilled and/or heated air in order to regulate the temperature of an associated room or building. As may be seen in  FIG. 1 , air conditioner unit  100  includes a casing  110  extends between an interior side portion  112  and an exterior side portion  114 . Interior side portion  112  of casing  110  and exterior side portion  114  of casing  110  are spaced apart from each other along the lateral direction L. Thus, interior side portion  112  of casing  110  may be positioned at or contiguous with an interior atmosphere, and exterior side portion  114  of casing  110  may be positioned at or contiguous with an exterior atmosphere. The air conditioner unit  100  also includes components for circulating air such as an outdoor fan  136  in the outdoor portion  150  and an indoor blower fan  134  (hereinafter, “indoor fan  134 ,” such as may be seen in  FIG. 2 ) in the indoor portion  130 . Sealed system  120  includes components for transferring heat between the exterior atmosphere and the interior atmosphere. For example, sealed system  120  includes a compressor  122 , an interior heat exchanger or coil  124  and an exterior heat exchanger or coil  126 . 
     Casing  110  defines a mechanical compartment  116 . Sealed system  120  is disposed or positioned within mechanical compartment  116  of casing  110 . The sealed system  120  may be attached to the casing  110 , e.g., with mechanical fasteners such as screws. A front panel  118  is attached to the sealed system  120 , e.g., with a snap fit or interference fit, and a rear grill or screen  119  is mounted to casing  110 . The front panel  118  and the rear grill  119  hinder or limit access to mechanical compartment  116  of casing  110 . Front panel  118  is mounted to sealed system  120  such that the front panel  118  is positioned at interior side portion  112  of casing  110 , and rear screen  119  is mounted to casing  110  at exterior side portion  114  of casing  110 . Front panel  118  and rear screen  119  each define a plurality of holes that permit air to flow through front panel  118  and rear screen  119 , with the holes sized for preventing foreign objects from passing through front panel  118  and rear screen  119  into mechanical compartment  116  of casing  110 . 
     Air conditioner unit  100  also includes a drain pan or bottom tray  138  and a bulkhead assembly  140  positioned within mechanical compartment  116  of casing  110 . Sealed system  120  is positioned on bottom tray  138 . Thus, liquid runoff from sealed system  120  may flow into and collect within bottom tray  138 . Bulkhead assembly  140  may be mounted to bottom tray  138  and extend upwardly from bottom tray  138  to a top wall of casing  110 . Bulkhead assembly  140  limits or prevents air flow between interior side portion  112  of casing  110  and exterior side portion  114  of casing  110  within mechanical compartment  116  of casing  110 . Thus, bulkhead assembly  140  may divide mechanical compartment  116  of casing  110 . 
     Air conditioner unit  100  further includes a controller  146  with user inputs, such as buttons, switches and/or dials. Controller  146  regulates operation of the air conditioner unit  100 . Thus, controller  146  is in operative communication with various components of air conditioner unit  100 , such as components of sealed system  120  and/or a temperature sensor, such as a thermistor or thermocouple, for measuring the temperature of the interior atmosphere. In particular, controller  146  may selectively activate sealed system  120  in order to chill or heat air within sealed system  120 , e.g., in response to temperature measurements from the temperature sensor. 
     Controller  146  includes 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 conditioner unit  100 . The memory can represent random access memory such as DRAM, or read only memory such as ROM or FLASH. The processor executes programming instructions stored in the memory. The memory can be a separate component from the processor or can be included onboard within the processor. Alternatively, controller  146  may be constructed without using a microprocessor, e.g., using a combination of discrete analog and/or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software. 
     Referring now to  FIGS. 2 and 3 , an exemplary bulkhead assembly  140  according to one or more embodiments of the present disclosure is illustrated. As shown, bulkhead assembly  140  includes a bulkhead  200 . Bulkhead  200  generally defines a first surface facing a first direction and a second surface facing a second direction, the second surface opposite the first surface.  FIG. 2  illustrates a perspective view of an indoor side of bulkhead assembly  140 . As maybe seen in  FIG. 2 , bulkhead  200  includes an indoor surface  202  which faces the indoor portion  130  ( FIG. 1 ) of the air conditioner unit  100 .  FIG. 3  illustrates a perspective view of an outdoor side of the bulkhead assembly  140 . As may be seen in  FIG. 3 , bulkhead  200  includes an outdoor surface  204  which faces the outdoor portion  150  ( FIG. 1 ) of the air conditioner unit  100 . Thus, in at least some embodiments, the first surface of the bulkhead  200  may be the indoor surface  202 , which faces in a first direction towards the indoor portion  130 , and the second surface of the bulkhead  200  may be the outdoor surface  204  which faces in a second direction towards the outdoor portion  150 . Where the bulkhead assembly  140 , and in particular the bulkhead  200  thereof, are disposed between the indoor portion  130  and the outdoor portion  150 , e.g., as illustrated in  FIG. 1 , the first direction and the second direction will be opposing one another. For example, the indoor surface  202  of the bulkhead  200  may face away from the outdoor surface  204  of the bulkhead  200 . 
     As may be seen in  FIG. 2 , the bulkhead assembly  140  may include a cover  212  mounted to the indoor surface  202  of the bulkhead  200 . As may be seen in  FIG. 3 , the outdoor surface  204  of the bulkhead  200  may include an oblique portion  206  which is oblique to the vertical direction V and a cover  210  may be removably attached to the oblique portion  206  of the outdoor surface  204  of the bulkhead  200 . For example, the cover  210  may be removable attached to the oblique portion  206  with one or more mechanical fasteners, by a snap fit, and/or may be hingedly attached to the outdoor surface  204 . 
       FIG. 4  provides an enlarged and exploded view of a portion of  FIG. 2 . The bulkhead assembly  140  may generally include a first connector facing a first direction and a second connector facing a second direction opposite the first direction. As shown for example in  FIG. 4 , a printed circuit board  214  may be mounted to the indoor surface  202  of the bulkhead  200 . The printed circuit board  214  may include an indoor surface  216  facing the indoor portion  130  ( FIG. 1 ) of the air conditioner unit  100 . At least one indoor connector  218  may be disposed on the bulkhead  200  and facing the indoor portion  130  of the air conditioner unit  100 . For example, as illustrated in  FIG. 4 , the at least one indoor connector  218  may be one or more electrical connectors mounted on the indoor surface  216  of the printed circuit board  214 . The at least one indoor connector  218  may include a plurality of indoor connectors  218  configured for connecting to a corresponding number of indoor components. Such indoor components may include, for example, one or more temperature sensors, e.g., thermistors, disposed in the indoor portion  130  of the air conditioner unit  100  and configured for measuring an indoor temperature, the indoor fan  134  and/or a motor thereof, and other similar components which may be disposed in the indoor portion  130 , as will be understood by those of skill in the art. The structure and function of such components, e.g., temperature sensors, are well understood by those of skill in the art and, as such, are not described or shown in further detail herein for the sake of clarity and concision. In at least some embodiments, the first connector mentioned above may be the indoor connector  218 , or one of a plurality of indoor connectors  218 , e.g., as illustrated in  FIG. 4 , where the first direction which the first connector faces is towards the indoor portion  130 . 
     As best seen in  FIG. 4 , the cover  212  may be mounted to the indoor surface  202  of the bulkhead  200  over the printed circuit board  214  such that the cover  212  is disposed between the printed circuit board  214  and the indoor portion  130  ( FIG. 1 ) of the air conditioner unit  100 . 
       FIG. 5  illustrates an enlarged view of a portion of  FIG. 3 , with the cover  210  removed to reveal an opening  208 . Also, the printed circuit board  214 , in particular an outdoor surface  220  thereof, may be seen through the opening  208 . At least one outdoor connector  222  may be disposed on the bulkhead  200  and facing the outdoor portion  150  of the air conditioner unit  100 . For example, as illustrated in  FIG. 5 , the at least one outdoor connector  222  may be one or more electrical connectors mounted on the outdoor surface  220  of the printed circuit board  214 . The at least one outdoor connector  222  may include a plurality of outdoor connectors  222  configured for connecting to a corresponding number of outdoor components. Such outdoor components may include, for example, the outdoor fan  136 , one or more temperature sensors, e.g., thermistors, similar to the exemplary indoor temperature sensors described above, and/or one or more valves and associated actuators. For example, the outdoor components may include an internal condensation recirculation valve, a makeup air module, as well as various other suitable outdoor components, as will be understood by those of skill in the art. The structure and function of such components, e.g., valves and/or makeup air modules, are well understood by those of skill in the art and, as such, are not described or shown in further detail herein for the sake of clarity and concision. In at least some embodiments, the second connector mentioned above may be the outdoor connector  222 , or one of a plurality of outdoor connectors  222 , e.g., as illustrated in  FIG. 5 , where the second direction which the second connector faces is towards the outdoor portion  150 . 
     As best seen in  FIG. 5 , the opening  208  may be aligned with the at least one outdoor connector  222 , such that the opening  208  is configured to permit access to the at least one outdoor connector  222  from the outdoor portion  150  of the air conditioner unit  100 . As generally shown throughout  FIGS. 3-5 , the outdoor surface  204  of the bulkhead  200  may include an oblique portion  206  which extends at an oblique angle α to the vertical direction V and the opening  208  may be defined in the oblique portion  206 . Thus, as shown, the oblique portion  206  of the outdoor surface  204  is also oblique to the indoor surface  202  of the bulkhead  200 . For example, the indoor surface  202  may be generally or predominantly oriented within a vertical-lateral plane defined by the vertical direction V and the lateral direction L, such that the oblique portion  206  of the outdoor surface  204  is oblique to the indoor surface  202 , e.g., when viewed from the side, such as looking along the lateral direction L, and/or within a vertical-transverse plane. The oblique portion  206  may advantageously provide access to the at least one outdoor connectors  222 , e.g., via the opening  208  as mentioned, while also accommodating additional components within the bulkhead assembly  140 , e.g., tubing connected to the sealed system  120 , such as copper tubing. The oblique portion  206  may be close to vertical. As mentioned, the oblique portion  206  may be disposed at an angle α with the vertical direction. For example, the angle α may be less than about fifty degrees, such as less than about forty-five degrees, such as less than about thirty-five degrees, such as about thirty degrees or less. 
     The air conditioner unit of the present disclosure provides several advantages. For example, providing the outdoor connectors on an outdoor-facing surface reduces the time and expense needed to assemble and/or disassemble the unit, such as during manufacture or maintenance, etc. Also by way of example, the opening in the outdoor surface of the bulkhead advantageously provides access to the outdoor connectors from the outdoor portion of the air conditioner unit, promoting ease of assembly and reducing the amount of materials, e.g., length of copper wires, needed to make up the connections during assembly and/or maintenance of the air conditioner unit. 
     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.