Patent application title:

ELECTROMAGNETIC LEAK MITIGATION SYSTEM

Publication number:

US20250369638A1

Publication date:
Application number:

19/209,145

Filed date:

2025-05-15

Smart Summary: A system has been created to find and fix leaks in refrigerants. It has two separate areas inside a cabinet, with a sensor in one area that detects leaks. A controller collects data about any leaks and manages a fan in the other area. The fan helps move air, and there is a door that can open to connect the two areas. The controller can adjust how fast the fan runs and when the door opens or closes. 🚀 TL;DR

Abstract:

A leak detection and mitigation system is disclosed. The system includes a cabinet comprising first and second compartments separated from each other by a separation wall, a sensor disposed in the second compartment and configured to detect the refrigerant leak, a controller configured to receive refrigerant leak data, a fan disclosed in the first compartment and communicating with the controller, and a door disposed on the separation wall between the first and second compartments and configured to be open to allow communication between the first and second compartments. The controller can control an airflow rate of the fan and opening and closing of the door.

Inventors:

Assignee:

Applicant:

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Classification:

F24F11/77 »  CPC further

Control or safety arrangements; Control systems characterised by their outputs; Constructional details thereof for controlling the supply of treated air, e.g. its pressure for controlling air flow rate or air velocity by controlling the speed of ventilators

F24F13/20 »  CPC further

Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening Casings or covers

F24F11/36 »  CPC main

Control or safety arrangements for purposes related to the operation of the system, e.g. for safety or monitoring; Responding to malfunctions or emergencies to leakage of heat-exchange fluid

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. Provisional Application Ser. No. 63/654,488, entitled “ELECTROMAGNETIC LEAK MITIGATION SYSTEM,” filed May 31, 2024, and which is herein incorporated by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates to cooling systems, more specifically, to systems and methods for refrigerant leak management in cooling systems.

BACKGROUND

Cooling systems are widely used in various applications where fluids (e.g., air or water) need to be cooled. These systems are commonly found in heating, ventilation, and air conditioning (HVAC) applications, such as those used in spaces housing electronic devices (e.g., offices, data centers) to maintain optimal environmental conditions. These HVAC systems are essential for managing the temperature and humidity within environments where electronic equipment is operating.

FIG. 1 illustrates a typical cooling system 100, such as one used in a building (e.g., a data center 102). The system includes both an indoor unit 104 and an outdoor unit 106. The indoor unit 104 typically houses key components like the evaporator, fan, compressor, and expansion valve, while the outdoor unit 106 contains a condenser coil, fan, and pump. These two units are connected via a closed refrigeration circuit, allowing for heat exchange between the indoor and outdoor environments. FIG. 2 further illustrates an indoor unit 200 (corresponding to indoor unit 104 from FIG. 1), which consists of a cabinet 210 containing multiple compartments. In this configuration, the evaporator and fan 240 are located in the first compartment 220, while the compressor is housed in a second, enclosed compartment 230. The refrigerant within the system undergoes phase changes at specific temperatures and pressures, facilitating heat transfer through the latent heat of vaporization.

Common refrigerants used in commercial HVAC systems include R-410A, R-407C, and R-134a, which are hydrofluorocarbons (HFCs) known for their non-flammability and low toxicity. However, as regulatory pressure to reduce global warming potential (GWP) increases, the HVAC industry has shifted toward refrigerants with lower GWP. Many of these low-GWP refrigerants, classified by ASHRAE as A2L (mildly flammable), include substances like R-1234yf, R-1234ze, R-452B, R-454B, and R-32. According to standards like UL 60335-2-40, A2L refrigerant systems are subject to specific charge level requirements, where charges below a predetermined limit (M1) are exempt from leak detection and mitigation protocols. Despite their reduced flammability, A2L refrigerants still present a combustion risk in the event of a leak. Therefore, it is crucial to detect any leaks in HVAC systems that utilize these refrigerants, particularly in confined spaces such as the indoor unit.

Current HVAC systems often experience refrigerant coil failures, particularly in condenser or evaporator coils, which can lead to leaks. Traditional methods of detecting refrigerant leaks or mitigating their impact have been inadequate, especially when distinguishing between actual refrigerant leaks and ambient emissions from hydrocarbons found in cleaning solvents or other materials commonly used in commercial buildings. If a refrigerant leak occurs within an enclosed space, such as the first compartment of the indoor unit, and an A2L refrigerant is present, there is an increased risk of combustion. This risk highlights the need for enhanced refrigerant leak detection and mitigation systems to ensure safety and compliance with evolving environmental regulations.

Given these challenges, there is a pressing need for improved refrigerant leak detection and mitigation systems capable of reducing the risk of failure and danger in HVAC systems. Such systems would also ensure compliance with stringent environmental regulations, including those recently enacted by the Environmental Protection Agency (EPA), and would address long-standing concerns in the HVAC servicing industry.

SUMMARY

Embodiments described herein relate to methods and systems for cooling data centers, specifically addressing refrigerant leak detection and mitigation. The systems and methods disclosed utilize an electromagnetic approach, providing an effective solution that is both cost-efficient and simple to implement. This innovative design meets existing industry standards while avoiding unnecessary complexity or high costs.

Various embodiments described herein enable detecting of refrigerant leaks in an enclosed space and mitigating with a simple configuration. Some embodiments include a system for detecting and mitigating a refrigerant leak. The system includes a cabinet comprising first and second compartments separated from each other by a separation wall; a sensor disposed in the second compartment and configured to detect the refrigerant leak; a controller configured to receive refrigerant leak data; a fan disclosed in the first compartment and communicating with the controller; a door disposed on the separation wall between the first and second compartments and configured to be open to allow communication between the first and second compartments, the door configured to be open or closed by the controller. The controller is configured to control an airflow rate of the fan and opening and closing of the door.

In some embodiments, the refrigerant leak data comprises at least one of a refrigerant concentration, a temperature, a pressure, or a humidity. Based on the refrigerant leak data, when a refrigerant leak value is equal to or greater than a reference value, the controller increases the airflow rate of the fan.

In some embodiments, the door includes a first magnet disposed on the separation wall in the first compartment; a second magnet disposed on the door facing the first magnet to be in contact with the first magnet when the door is closed; and a hinge having a gravity damper and disposed away from the first and second magnets. The controller is configured to control a voltage supply to the first and second magnets based on the refrigerant leak data. In some embodiments, based on the refrigerant leak data, when the refrigerant leak value is equal to or greater than the reference value, the controller stops the voltage supply to the first and second magnets thus allowing the fan to freely rotate.

In some embodiments, the door is configured to rotate on the hinge. The controller controls the fan to increase the airflow rate from a normal operating airflow rate to become a minimally required airflow rate to rotate the door, thus allowing the communication between the first and second compartments. When there is no refrigerant leak detected, the fan is controlled to run at the normal operating airflow rate during a normal operation. When there is the refrigerant leak determined, the fan is controlled to run at the minimally required airflow rate which depends on a dimension and a weight of the door. When the refrigerant leak value becomes less than the reference value, the controller activates the voltage supply to the first and second magnets.

In some embodiments, the sensor is disposed on a bottom of the second compartment. The sensor includes at least one of a temperature sensor, a pressure sensor, or a humidity sensor. The controller communicates with a door hinge and is configured to lock and unlock the door hinge to open the door to allow communication between the first and second compartments based on the refrigerant leak data. The first compartment comprises a compressor, and the second compartment comprises an evaporator coil.

In accordance with another embodiment of the present disclosure, a cooling system having an indoor unit and an outdoor unit is provided. The indoor unit is disposed inside a building and the outdoor unit is disposed outside the building, and the indoor unit includes first and second compartments separated from each other. The second compartment includes: a sensor disposed on a bottom side of the second compartment and configured to detect a refrigerant leak; and a controller configured to receive refrigerant leak data from the sensor. The first compartment includes: a fan disposed at a top side of the first compartment and configured to communicate with the controller; and a door disposed on a separation wall between the first and second compartments, wherein the door is configured to be selectively open and closed by the controller based on the refrigerant leak data.

In accordance with still another embodiment of the present disclosure, a method of controlling refrigerant leak mitigation for an indoor unit of a cooling system is provided. The indoor unit comprises first and second compartments separated from each other. The method includes detecting, by a sensor, a sensing value in the second compartment; determining, by a controller, whether the sensing value is higher than a threshold value; upon determining that the sensing value is higher than the threshold value, stopping, by the controller, a voltage supply to a door between the first and second compartments; and increasing, by the controller, an airflow of a fan disposed in the first compartment to be a minimally required airflow to open the door. In some embodiments, stopping the voltage supply comprises stopping the voltage supply to the magnets that are configured to lock the door when energized.

Other aspects and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like elements:

FIG. 1 shows an example of a typical cooling system for a data center;

FIG. 2 shows a perspective of an indoor unit of the typical cooling system of FIG. 1;

FIG. 3 shows a perspective of an indoor unit of a cooling system having an electromagnetic leak mitigation system according to embodiments of the present disclosure;

FIG. 4A shows the electromagnetic leak mitigation system in a normal mode;

FIG. 4B shows the electromagnetic leak mitigation system in a leak detection mode; and

FIG. 5 shows a flowchart of controlling the ventilation of refrigerant leaks.

DETAILED DESCRIPTION

The figures described above and the written description of specific structures and functions below are not presented to limit the scope of what Applicants have invented or the scope of the appended claims. Rather, the Figures and written description are provided to teach any person skilled in the art to make and use the inventions for which patent protection is sought. Those skilled in the art will appreciate that not all features of a commercial embodiment of the inventions are described or shown for the sake of clarity and understanding. Persons of skill in this art will also appreciate that the development of an actual commercial embodiment incorporating aspects of the present inventions will require numerous implementation-specific decisions to achieve the developer's goal for the commercial embodiment. Such implementation-specific decisions may include and likely are not limited to, compliance with system-related, business-related, government-related, and other constraints, which may vary by specific implementation, location, and from time to time. While a developer's efforts might be complex and time-consuming in an absolute sense, such efforts would be, nevertheless, a routine undertaking for those of skill in this art having the benefit of this disclosure. It must be understood that the inventions disclosed and taught herein are susceptible to numerous and various modifications and alternative forms.

The use of a singular term, such as, but not limited to, “a,” is not intended as limiting of the number of items. The use of relational terms, such as, but not limited to, “top,” “bottom,” “left,” “right,” “upper,” “lower,” “down,” “up,” “side,” and the like are used in the written description for clarity in specific reference to the Figures and are not intended to limit the scope of the inventions or the appended claims. The terms “including” and “such as” are for illustrative purposes but not limited thereto. The terms “couple,” “coupled,” “coupling,” “coupler,” and like terms are used broadly herein and can include any method or device for securing, binding, bonding, fastening, attaching, joining, inserting therein, forming thereon or therein, communicating, or otherwise associating, for example, mechanically, magnetically, electrically, chemically, operably, directly or indirectly with intermediate elements, one or more pieces of members together and can further include without limitation integrally forming one functional member with another in a unity fashion. The coupling can occur in any direction, including rotationally. Further, all parts and components of the disclosure that are capable of being physically embodied inherently include imaginary and real characteristics regardless of whether such characteristics are expressly described herein, including but not limited to characteristics such as axes, ends, inner and outer surfaces, interior spaces, tops, bottoms, sides, boundaries, dimensions (e.g., height, length, width, thickness), mass, weight, volume, and density, among others.

The introduction of A2L refrigerants requires enhanced leak mitigation measures to meet standards for direct expansion units. Units with separated compressor and fan sections present a particular risk, as any refrigerant leaks in the compressor section can accumulate at the bottom, with no means of escaping. By incorporating an electromagnetic system within the compressor section, the present system offers an effective and affordable solution for handling refrigerant leaks. This approach ensures compliance with existing standards while avoiding unnecessary complexity and high costs.

Specifically, indoor units of HVAC systems, which include an enclosed compressor section and a coil section with a fan, are particularly vulnerable to refrigerant leaks. In the compressor section, the presence of high pressures, moving components, and numerous fittings and brazes increases the likelihood of leaks. While refrigerant leaks in the coil section can be quickly dispersed due to the proximity to the fan, the compressor section is isolated from the airflow, allowing refrigerant to accumulate and concentrate, creating a greater risk.

The proposed leak mitigation systems are designed for direct expansion units that feature a separate indoor compressor section and utilize A2L refrigerants. With the tightening of EPA regulations, many manufacturers are turning to these new refrigerants. Although A2L refrigerants are permitted, they introduce new risks of flammability and asphyxiation not present with earlier refrigerants. Consequently, it is essential to address refrigerant leaks to meet safety standards.

In one embodiment, a refrigerant leak sensor is placed in both the compressor and coil sections to monitor the concentration of A2L refrigerant. Two key concentration thresholds must be considered to comply with A2L refrigerant standards: the Refrigeration Concentration Limit (RCL) and the Low Flammability Limit (LFL). The RCL defines the concentration at which asphyxiation risks become significant and triggers leak mitigation to prevent a potential flammable event. The LFL, when reached, presents an immediate combustion risk if temperatures rise or if sparks or open flames are present.

The proposed systems feature an electromagnetic door placed on the wall separating the compressor and coil sections of the indoor unit. During normal operation, a voltage is applied to a magnet that keeps the door sealed. When the leak sensors detect a refrigerant leak, they send a signal to a controller, which deactivates the voltage, causing the door to open and allowing air to flow between the compressor and coil sections. The pressure differential between the compressor and fan sections forces the door open, mitigating the leak. Once the refrigerant concentration returns to a safe level, the voltage is reapplied, closing the door. This process is crucial to ensure that no gaps are left in the compressor section wall during normal operation, as such gaps would reduce capacity and efficiency, directly affecting system performance and customer satisfaction.

FIG. 3 illustrates a perspective view of an indoor unit of a cooling system featuring an electromagnetic leak mitigation system, in accordance with embodiments of the present disclosure. FIG. 4A shows the electromagnetic leak mitigation system in normal operation mode, while FIG. 4B depicts the system in leak detection mode.

In certain embodiments, an indoor unit 300 for a cooling system comprises a housing or cabinet 310 with at least one enclosed compartment. For example, the cabinet 310 may include a first compartment 320 containing an evaporator, refrigerant coils, and a blower fan 340, and a second compartment 330 housing a compressor. The second compartment 330 is an enclosed space that can be selectively opened or closed by a door 350. When the door 350 is closed, the first and second compartments 320, 330 are isolated from one another. When the door 350 is open, the two compartments can communicate. The opening and closing of the door 350 can be controlled based on sensor data, as further described with reference to FIGS. 4A and 4B.

FIGS. 4A and 4B show an indoor unit 400, corresponding to indoor unit 300 in FIG. 3, with a cabinet 410 housing two compartments: a first compartment 420 and a second compartment 430. Similar to the first compartment 220 of FIG. 2, the first compartment 420 of FIGS. 4A and 4B houses the evaporator (not shown), which includes a refrigerant coil and a blower fan 440. In general, air conditioning systems feature two coils: condenser coils (outside) and evaporator coils (inside). The evaporator coil is often referred to as the “cold” coil because it absorbs heat from the indoor air, which is blown across the coil by the fan 440. The condenser coil, or “warm” coil, rejects heat when outdoor air is blown over it.

The evaporator coil is positioned near the blower fan 440, where it absorbs heat and cools the indoor air. The refrigerant within the coil absorbs heat from the air, causing the refrigerant to warm and evaporate. As the air cools, water vapor condenses on the evaporator coil and drips into a condensate pan, which drains the water outside to reduce humidity.

FIG. 4A shows an embodiment where the indoor unit cabinet 410 includes a door assembly 450 separating the first compartment 420 from the second compartment 430. Under normal operating conditions, when no faults or leaks are present, the door assembly 450 remains closed. The door assembly 450 can include a door 455 that can be locked through electromagnetism. The door assembly 450 further includes a first magnet 460 mounted to a separation wall 412, dividing the two compartments 420 and 430. The door assembly 450 also includes a second magnet 470, which contacts the first magnet 460 when the door assembly 450 is closed.

During normal operation, when the system is functioning properly, a magnetic field, generated by energizing the first and second magnets 460 and 470, holds the door 455 securely closed. If a refrigerant leak is detected, the power supply to the first and second magnets 460 and 470 is cut, deactivating the magnetic field, which allows the door 455 to open under external force. The door 455 is hinged to the separation wall 412 using a gravity damper 480 and a hinge 482. A gravity damper 480 allows airflow in one direction while preventing reverse airflow, and it can be either gravity-operated or motorized. In another embodiment, the hinge 482 may include a locked configuration in which the door 455 cannot be rotated and an unlocked configuration in which the door 455 can be rotated freely. The locked and unlocked configurations of the hinge 482 can be set by a controller 492.

In typical operation, the door assembly 450 remains securely locked by the first and second magnets 460 and 470, even if external forces (such as wind from the fan 440) are applied. The fan 440 operates continuously at a set speed to maintain airflow over the evaporator coils, removing heat and keeping the interior at a constant, predetermined temperature. The fan 440 works in coordination with the compressor.

In some embodiments, a refrigerant leak sensor 490 is positioned at the bottom of the second compartment 430, connected to a controller 492. Since A2L refrigerant gases are heavier than air, in the event of a leak, the A2L refrigerant will accumulate near the bottom of the second compartment 430. The sensor 490 measures a fluid characteristic of the air in the second compartment 430 and generates a sensor signal to be received by the controller 492. In the illustrated embodiment, the sensor 490 measures the refrigerant concentration in the second compartment 430. The sensor 490 may be designed to detect various types of refrigerants, such as non-toxic and flammable A2L refrigerants, or non-toxic and non-flammable refrigerants like A1, among others. In further embodiments, the sensor 490 may also measure fluid characteristics such as temperature, relative humidity, or barometric pressure.

The controller 492 can trigger a response, such as disconnecting power to the system components (e.g., the compressor, the evaporator, the condenser, or one or more fans) if the refrigerant concentration exceeds a lower flammability limit (LFL) or lower explosive limit (LEL) for the refrigerant. Both LFL and LEL define the threshold at which the concentration of a flammable gas (like refrigerant) in air becomes capable of ignition. For example, the controller 492 may deactivate a relay or switch if the refrigerant concentration exceeds a certain percentage of the LFL, such as 25%. The relay is typically energized during normal operation, but if the LFL is exceeded, the relay de-energizes, ensuring the system operates safely.

Additionally or alternatively, in some embodiments, when the leak is detected or determined in the second compartment 430 which is an enclosed space, the controller 492 can first turn off the power supply to the magnets 460, 470. Thus, the door 455 can be freely rotated about the hinge 482 with the help of external force. The controller 492 may further control the fan 440 to increase a normal airflow Q to be a minimally required airflow (“Qmin airflow”) to lift up the door 455 away from the separating wall 412, rotated by the hinge 482, as shown in FIG. 4B. Here, the airflow Q is the volume of air that is produced by a fan measured by time. In this case, the airflow of the fan 440 can be measured in cubic meters per minute (m3/min) in metric units, or cubic feet per minute (CFM) in imperial units. As an example, Qmin airflow can be represented by the following equation:

Q min = 3 ⁢ 0 × m c L ⁢ F ⁢ L ,

where Q is a minimum ventilation airflow in m3/h, Mc is a refrigerant charge in system in kg, and LFL is a lower flammability limit in kg/m3.

As the airflow increases to Qmin airflow, which represents the minimum airflow as denoted when a refrigerant leak is detected, the door assembly 450 is configured to be open as described above, thus dragging the leak to travel from the second compartment 430 to the first compartment 420 by the fan 440. The Qmin airflow rates may range from, e.g., 10 to 50 m3/h. This range can change based on the size of the unit/system. When the leakage of the refrigerant is detected, the Qmin of the fan 440 is set to open the door 440 forcibly. Now, the Qmin airflow can drag the refrigerant leak to the first compartment 420. Based on the Qmin airflow value, the size and weight of the door 455 can be determined. That is, even if the door 445 can be freely rotated by deactivating the magnetic field, there needs a minimally required force, in this case, the minimum airflow Qmin, to be able to lift up the door 455.

Although the door 455 is described as an electromagnetic door for locking and unlocking, it is not limited to this configuration. The door may be any type of door that can be controlled to open and close via a controller. Similarly, the gravity damper 480 and hinge 482 mechanisms are not restricted to the specific descriptions and illustrations presented. Any mechanism that allows for the described opening and closing of the door can be adapted for use in the leak mitigation system.

Additionally, the electromagnetic leak detection and mitigation system can be installed in any HVAC unit that uses A2L refrigerants, such as R454B, and does not have an easily accessible section for refrigerant leak sensors. This system can be applied to units such as DS units, DSE units, PDX units, and similar configurations.

FIG. 5 shows a flowchart depicting the operation of the refrigerant leak ventilation process. The process begins at S510, where a refrigerant leak is detected by measuring the refrigerant concentration using the sensor 490, as previously described. Control proceeds to S520, where it is determined whether the measured refrigerant concentration exceeds a threshold, such as 25% of the lower flammability limit (LFL).

If the refrigerant concentration is below the threshold, control returns to S510 to continue monitoring. If the refrigerant concentration exceeds the threshold, control proceeds to S530, where a leak notification is sent to the controller 492. Next, at S540, the voltage or power to the door assembly 450 is disconnected, for example, by de-energizing the relay connected to the first and second magnet 460, 470, allowing the door 455 to open. In another embodiment, a single magnet of the first magnet 460 or the second magnet 470 is de-energized by the relay. In a further embodiment, the relay is also connected to the sensor 490, which would be de-energized when a leak notification is received.

Control then moves to S550, where the fan 440 is activated to increase the airflow rate to the Q_min value. Once the refrigerant concentration decreases back below the threshold, control proceeds to S560, where the airflow rate is returned to the normal operating rate, and power or voltage is restored to the first and second magnets 460, 470 of the door assembly 450, closing it once again.

In this application, including the definitions below, the term “module” or the term “controller” may be replaced with the term “circuit.” The term “module” refers to or includes: an Application Specific Integrated Circuit (ASIC); a digital, analog, or mixed analog/digital discrete circuit; a digital, analog, or mixed analog/digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor circuit (shared, dedicated, or group) that executes code; a memory circuit (shared, dedicated, or group) that stores code executed by the processor circuit; other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip.

The module may include one or more interface circuits. In some examples, the interface circuits may include wired or wireless interfaces that are connected to a local area network (LAN), the Internet, a wide area network (WAN), or combinations thereof. The functionality of any given module of the present disclosure may be distributed among multiple modules that are connected via interface circuits. For example, multiple modules may allow load balancing. In a further example, a server (also known as remote, or cloud) module may accomplish some functionality on behalf of a client module.

The term code, as used above, may include software, firmware, and/or microcode, and may refer to programs, routines, functions, classes, data structures, and/or objects. The term shared processor circuit encompasses a single processor circuit that executes some or all code from multiple modules. The term group processor circuit encompasses a processor circuit that, in combination with additional processor circuits, executes some or all code from one or more modules. References to multiple processor circuits encompass multiple processor circuits on discrete dies, multiple processor circuits on a single die, multiple cores of a single processor circuit, multiple threads of a single processor circuit, or a combination of the above. The term shared memory circuit encompasses a single memory circuit that stores some or all code from multiple modules. The term group memory circuit encompasses a memory circuit that, in combination with additional memories, stores some or all code from one or more modules.

The term memory circuit is a subset of the term computer-readable medium. The term computer-readable medium, as used herein, does not encompass transitory electrical or electromagnetic signals propagating through a medium (such as on a carrier wave); the term computer-readable medium may therefore be considered tangible and non-transitory. Non-limiting examples of a non-transitory, tangible computer-readable medium are nonvolatile memory circuits (such as a flash memory circuit, an erasable programmable read-only memory circuit, or a mask read-only memory circuit), volatile memory circuits (such as a static random access memory circuit or a dynamic random access memory circuit), magnetic storage media (such as an analog or digital magnetic tape or a hard disk drive), and optical storage media (such as a CD, a DVD, or a Blu-ray Disc).

The apparatuses and methods described in this application may be partially or fully implemented by a special purpose computer created by configuring a general purpose computer to execute one or more particular functions embodied in computer programs. The functional blocks, flowchart components, and other elements described above serve as software specifications, which can be translated into the computer programs by the routine work of a skilled technician or programmer.

The computer programs include processor-executable instructions that are stored on at least one non-transitory, tangible computer-readable medium. The computer programs may also include or rely on stored data. The computer programs may encompass a basic input/output system (BIOS) that interacts with hardware of the special purpose computer, device drivers that interact with particular devices of the special purpose computer, one or more operating systems, user applications, background services, background applications, etc.

The computer programs may include: (i) descriptive text to be parsed, such as HTML (hypertext markup language), XML (extensible markup language), or JSON (JavaScript Object Notation) (ii) assembly code, (iii) object code generated from source code by a compiler, (iv) source code for execution by an interpreter, (v) source code for compilation and execution by a just-in-time compiler, etc. As examples only, source code may be written using syntax from languages including C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, Java®, Fortran, Peri, Pascal, Curl, OCaml, Javascript®, HTML5 (Hypertext Markup Language 5th revision), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Flash®, Visual Basic®, Lua, MATLAB, SIMULINK, and Python®.

None of the elements recited in the claims are intended to be a means-plus-function element within the meaning of 35 U.S.C. § 112(f) unless an element is expressly recited using the phrase “means for,” or in the case of a method claim using the phrases “operation for” or “step for.”

Although the terms first, second, third, etc. may be used herein to describe various elements, pumps, condenser fans, compressors, circuits, components and/or modules, these items should not be limited by these terms. These terms may be only used to distinguish one item from another item. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first item discussed herein could be termed a second item without departing from the teachings of the example implementations.

Process flowcharts discussed herein illustrate the operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the blocks might occur out of the order depicted in the figures. For example, blocks shown in succession may be executed substantially concurrently. It will also be noted that each block of flowchart illustration can be implemented by special-purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.

The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Claims

What is claimed is:

1. A system for detecting and mitigating a refrigerant leak, the system comprising:

a cabinet comprising a first compartment and a second compartment separated by a separation wall;

a sensor disposed in the second compartment, the sensor configured to generate a fluid characteristic signal;

a fan disposed in the first compartment;

a door assembly disposed on the separation wall between the first compartment and the second compartment, the door assembly moveable between an open position to allow fluid communication between the first compartment and the second compartment and a closed position in which the first compartment is fluidly sealed from the second compartment, and

a controller in electrical communication with at least the sensor, the fan, and the door assembly, the controller configured to receive the fluid characteristic signal from the sensor, the controller configured to set an airflow rate of the fan, the controller configured to transition the door assembly between the open position and the closed position.

2. The system of claim 1, wherein the fluid characteristic signal describes at least one of a refrigerant concentration, a temperature, a pressure, or a humidity.

3. The system of claim 2, wherein, the controller determines the airflow rate of the fan based on the comparison between a refrigerant leak value, determined from the fluid characteristic signal, and a reference value.

4. The system of claim 3, wherein the door assembly comprises:

a door;

a first magnet disposed on the separation wall, the first magnet facing the first compartment;

a second magnet disposed on the door to be selectively attracted to the first magnet; and

a door hinge about which the door rotates, the door hinge having a gravity damper, the door hinge disposed away from the first magnet and the second magnet,

wherein the controller is configured to control a voltage supply to the first magnet and the second magnet based on the comparison between a refrigerant leak value, determined from the fluid characteristic signal, and a reference value.

5. The system of claim 4, wherein, based on the refrigerant leak data, when the refrigerant leak value is equal to or greater than the reference value, the controller stops the voltage supply to the first magnet and the second magnet thus allowing the door to freely rotate.

6. The system of claim 5, wherein the controller changes the airflow rate of the fan from a normal operating airflow rate to become a minimally required airflow rate to rotate the door, thus allowing the communication between the first and second compartments.

7. The system of claim 5, wherein, when there is no refrigerant leak detected, the fan is controlled to run at the normal operating airflow rate during a normal operation, and wherein, when there is the refrigerant leak determined, the fan is controlled to run at the minimally required airflow rate which depends on a dimension and a weight of the door.

8. The system of claim 7, wherein, when the refrigerant leak value becomes less than the reference value, the controller activates the voltage supply to the first magnet and the second magnet.

9. The system of claim 8, wherein, when the refrigerant leak value becomes less than the reference value, the controller is further configured to command to operate at the normal operating airflow rate.

10. The system of claim 1, wherein, the sensor is disposed on a bottom of the second compartment.

11. The system of claim 1, wherein the sensor includes at least one of a refrigerant detection sensor, a temperature sensor, a pressure sensor, or a humidity sensor.

12. The system of claim 1, wherein the controller communicates with a door hinge and is configured to lock and unlock the door hinge to open the door to allow communication between the first and second compartments based on a comparison between a refrigerant leak value, determined from the fluid characteristic signal, and a reference value.

13. The system of claim 1, wherein the first compartment comprises a compressor, and the second compartment comprises an evaporator coil.

14. A cooling system having an indoor unit and an outdoor unit, wherein the indoor unit is disposed inside a building and the outdoor unit is disposed outside the building, and wherein the indoor unit includes a first compartment and a second compartment separated from each other by a separation wall,

wherein the second compartment comprises:

a sensor disposed on a bottom side of the second compartment, the sensor is configured to generate a fluid characteristic signal, and

a controller configured to receive the fluid characteristic signal from the sensor, and

wherein the first compartment comprises:

a fan disposed at a top side of the first compartment and configured to communicate with the controller; and

wherein the separation wall comprises:

a door assembly configured to be selectively opened and closed by the controller based on the fluid characteristic signal.

15. The system of claim 14, wherein the fluid characteristic signal is proportional at least one of a refrigerant concentration, a temperature, a pressure, or a humidity.

16. The system of claim 15, wherein the controller determines the airflow rate of the fan based on the comparison between a refrigerant leak value, determined from the fluid characteristic signal, and a reference value.

17. The system of claim 16, wherein the door assembly comprises:

a door;

a first magnet disposed on the separation wall in the first compartment;

a second magnet disposed on the door facing the first magnet to be in contact with the first magnet when the door is closed; and

a hinge having a gravity damper and disposed away from the first magnet and the second magnet,

wherein the controller is configured to control a voltage supply to the first magnet and second magnet based on the fluid characteristic signal.

18. The system of claim 17, wherein, based on the refrigerant leak data, when the refrigerant leak value is equal to or greater than the reference value, the controller stops the voltage supply to the first and second magnets thus allowing the door to freely rotate.

19. A method of controlling refrigerant leak mitigation for an indoor unit of a cooling system, wherein the indoor unit comprises first and second compartments separated from each other, the method comprising:

detecting, by a sensor, a sensing value in the second compartment;

determining, by a controller, whether the sensing value is higher than a threshold value;

upon determining that the sensing value is higher than the threshold value, stopping, by the controller, a voltage supply to a door assembly between the first and second compartments; and

increasing, by the controller, an airflow of a fan disposed in the first compartment to be a minimally required airflow to open a door of the door assembly.

20. The method of claim 18, wherein stopping the voltage supply comprises stopping a voltage supply to a magnet of the door assembly, wherein the magnet is configured to resist the opening of the door when receiving the voltage supply.

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