REFRIGERANT LEAK SENSOR MOUNTING BRACKET FOR AN AIR CONDITIONER UNIT

Description

FIELD OF THE INVENTION

The present disclosure relates generally to air conditioner units, and more particularly to a mounting bracket within air conditioner units such as ductless mini-split air conditioner units and related methods of installation.

BACKGROUND OF THE INVENTION

Air conditioners or conditioning units are conventionally utilized to adjust the temperature indoors—i.e. within structures such as dwellings and office buildings. Such units commonly include a closed refrigeration loop to heat or cool the indoor air. Typically, the indoor air is recirculated while being heated or cooled. A variety of sizes and configurations are available for such air conditioner units. For example, some units may have one portion installed indoors that is connected, by e.g., tubing carrying the refrigerant, to another portion located outdoors via a network of air ducts. These types of units are typically used for conditioning the air in larger spaces.

Another type of unit, sometimes referred to as a ductless mini-split system unit, may be used for somewhat smaller to moderate-sized indoor spaces that are to be air conditioned. These units may include both an indoor portion and an outdoor portion separated by an exterior wall of a structure such as a dwelling or office building with a connection by refrigerant piping and wiring, without a network of air ducts. Frequently, multiple ductless mini-split system units may be installed in a single location or facility, e.g. such as an apartment complex with a single split system for each apartment unit.

Within the ductless mini-split system units, there currently exists a plurality of mounting brackets for various components. An example of one such bracket includes a strain relief bracket, which supports the tension and stress placed on the power wires leading to the terminal block. Also, to comply with industry guidelines or government regulations, a refrigerant leak sensor is mounted via a separate bracket in the unit at a different internal location to detect gas levels. The plurality of brackets located within the unit add costs, and placement options are limited due to spatial constraints. Additionally, in many existing designs, the location of the mounted refrigerant leak sensor can make accessibility thereto difficult for service requirements.

Accordingly, improved air conditioner units and associated methods for obtaining better internal space utilization would be useful. More specifically, air conditioner units such as ductless mini-split system units and associated methods of assembly that can efficiently utilize space, reduce the number of parts therein, and increase service accessibility would be particularly beneficial.

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 one exemplary embodiment, an air conditioner unit is provided, including an indoor portion having an indoor heat exchanger positioned therein, an outdoor portion having an outdoor heat exchanger positioned therein, a refrigerant conduit extending between the indoor portion and the outdoor portion, an angled mounting bracket located within the indoor portion having a first portion defining a first plane and a second portion positioned adjacent to the first portion defining a second plane, a first mounting structure defined by the first portion of the angled mounting bracket, the first mounting structure being configured to receive an auxiliary component of the air conditioner unit, a second mounting structure defined by the second portion of the angled mounting bracket, the second mounting structure being configured to receive a refrigerant leak sensor, and a refrigerant leak sensor coupled to the second mounting structure of the second portion of the angled mounting bracket.

In another exemplary embodiment, an angled mounting bracket is provided. The angled mounting bracket includes a first portion of the angled mounting bracket defining a first plane, wherein the first portion of the angled mounting bracket comprises a plurality of fastening holes, wherein the plurality of fastening holes comprises at least one locating hole, a second portion of the angled mounting bracket positioned adjacent to the first portion defining a second plane, wherein the second portion of the angled mounting bracket comprises at least one fastening hole, a first mounting structure defined by the first portion of the angled mounting bracket, the first mounting structure being configured to receive a strain relief assembly, a second mounting structure defined by the second portion of the angled mounting bracket, the second mounting structure being configured to receive a refrigerant leak sensor, and an angle defined by the second portion of the angled mounting bracket extending from the first portion of the angled mounting bracket, the angle being between 65 degrees and 135 degrees.

In accordance with another embodiment, a method for assembling an air conditioner unit is provided. The air conditioner unit includes an indoor portion having an indoor heat exchanger positioned therein, an outdoor portion having an outdoor heat exchanger positioned therein, a refrigerant conduit extending between the indoor portion and the outdoor portion, a plurality of power wires leading to a plurality of terminal blocks located within the indoor portion and outdoor portion, respectively, an angled mounting bracket located within the indoor portion having a first portion defining a first plane and a second portion positioned adjacent to the first portion defining a second plane, a first mounting structure defined by the first portion of the angled mounting bracket, the first mounting structure being configured to receive an auxiliary component of the air conditioner unit, and a second mounting structure defined by the second portion of the angled mounting bracket, the second mounting structure being configured to receive a refrigerant leak sensor, wherein the second portion of the angled mounting bracket extends from the first portion of the angled mounting bracket to define an angle, the angle being between 65 degrees and 135 degrees. The method includes affixing a strain relief assembly to the first mounting structure of the first portion of the angled mounting bracket, coupling a refrigerant leak sensor to the second mounting structure of the second portion of the angled mounting bracket, and affixing the angled mounting bracket to the first portion of the air conditioner unit positioned proximate to an access panel located near a distal end of the indoor portion.

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 a front perspective view of an air conditioner unit, with a structure wall dividing an indoor portion and an outdoor portion for illustrative purposes, in accordance with one example embodiment of the present disclosure.

FIG. 2 provides a schematic view of a sealed system of the example air conditioner unit of FIG. 1 according to an example embodiment of the present subject matter.

FIG. 3 is a front perspective view of the outdoor portion of the example air conditioner unit of FIG. 1 according to an example embodiment of the present subject matter.

FIG. 4 is a rear perspective view of the outdoor portion of the example air conditioner unit of FIG. 1 according to an example embodiment of the present subject matter.

FIG. 5 is a front perspective view of the indoor portion with the display panel removed for clarity of the example air conditioner unit of FIG. 1 according to an example embodiment of the present subject matter.

FIG. 6 is a rear perspective view of the indoor portion with the access panel removed for clarity of the example air conditioner unit of FIG. 1 according to an example embodiment of the present subject matter.

FIG. 7 is a portion of the rear perspective view of the indoor portion with the access panel removed for clarity of the example air conditioner unit of FIG. 1 according to an example embodiment of the present subject matter.

FIG. 8 is an underneath perspective view of an angled mounting bracket in accordance with one embodiment of the present disclosure.

FIG. 9 is an above perspective view of the example angled mounting bracket of FIG. 8 in accordance with one embodiment of the present disclosure.

FIG. 10 is a side perspective view of the example angled mounting bracket of FIG. 8 in accordance with one embodiment of the present disclosure.

FIG. 11 illustrates a method for assembling an air conditioner unit in accordance with one embodiment of the present disclosure.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

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, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and may not be intended to signify location or importance of the individual components. 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 term “at least one of” in the context of, e.g., “at least one of A, B, and C” refers to only A, only B, only C, or any combination of A, B, and C. As used herein, the terms “coupled,” “fixed,” “attached to,” and the like refer to both direct coupling, fixing, or attaching, as well as indirect coupling, fixing, or attaching through one or more intermediate components or features, unless otherwise specified herein. In addition, here and throughout the specification and claims, range limitations may be combined and/or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.

Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,” “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and/or systems. For example, the approximating language may refer to being within a 10 percent margin, i.e., including values within ten percent greater or less than the stated value. In this regard, for example, 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, e.g., “generally vertical” includes forming an angle of up to ten degrees in any direction, e.g., clockwise or counterclockwise, with the vertical direction V.

The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” In addition, references to “an embodiment” or “one embodiment” does not necessarily refer to the same embodiment, although it may. Any implementation described herein as “exemplary” or “an embodiment” is not necessarily to be construed as preferred or advantageous over other implementations. Moreover, 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 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 explained herein, aspects of the present subject matter are generally directed to systems and an associated method for positioning an angled mounting bracket within an air conditioner unit. A refrigerant leak sensor may be affixed to the angled mounting bracket and oriented in a manner that aligns with industry guidelines or government regulations. Additionally, an auxiliary component of the air conditioner unit may also be coupled to the angled mounting bracket, thus reducing the number of parts used in an air conditioner unit. This approach may ensure that the refrigerant leak sensor is located as desired for service requirements, increasing accessibility thereto.

Referring now to FIG. 1, a front perspective view of an air conditioner unit 100 is provided according to example embodiments of the present disclosure. Generally, 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. The air conditioner unit 100 is an example of a ductless mini split air conditioner unit. As will be understood by those skilled in the art, an air conditioner unit 100 such as a ductless mini split air conditioner unit may be utilized in installations where placing ductwork is inconvenient or impractical. As illustrated, air conditioner unit 100 defines a vertical direction V, a lateral direction L, and a transverse direction T. Each direction V, L, T is perpendicular to each other, such that an orthogonal coordinate system is generally defined.

As used herein, the term “air conditioner unit” is applied broadly, and the present subject matter is not limited to the specific constructions described and illustrated herein. For example, although aspects of the present subject matter are described with reference to an example air conditioner unit 100 such as a ductless mini split system, it should be appreciated that aspects of the present subject matter may be equally applicable to other air conditioner unit types and configurations, such as single package vertical units (SPVUs), split heat pump systems, and/or a one-unit type air conditioner, also conventionally referred to as a room air conditioner or a packaged terminal air conditioner (PTAC).

As discussed below in greater detail, air conditioner unit 100 may include a sealed system 102 (i.e., sealed heat exchange system) to facilitate heat transfer and conditioning of a room where air conditioner unit 100 is located. Sealed system 102 includes components for transferring heat between the exterior atmosphere and the interior atmosphere, as discussed in greater detail below. In general, air conditioner unit 100 may be a self-contained or autonomous system for heating and/or cooling air.

According to an example embodiment, sealed system 102 and other components of air conditioner unit 100 may be disposed within an indoor portion 106 and an outdoor portion 108. In general, indoor portion 106 includes an indoor heat exchanger 132 positioned therein, and outdoor portion 108 includes an outdoor heat exchanger 134 positioned therein. In general, indoor portion 106 may also include a housing, e.g., display panel, that is mounted inside of a dwelling or structure, while outdoor portion 108 may include a housing that is mounted outside of a dwelling or structure. The housings included in indoor portion 106 and outdoor portion 108 may generally be constructed of any suitable number of layers and/or materials, e.g., to provide structural rigidity necessary to support components of air conditioner unit 100 while achieving the desired sound damping. In this regard, for example, structural frames included in indoor portion 106 and outdoor portion 108 may include a stamped metal layer, e.g., formed from stainless steel, painted external steel, or any other suitably rigid material, such as a rigid plastic.

In general, a structure wall 104 separates the indoor portion 106 from the outdoor portion 108, while the indoor portion 106 and outdoor portion 108 are connected via a power connection (not shown) and a refrigerant conduit 144 which may be utilized to flow refrigerant between various components of sealed system 102. Refrigerant conduit may include one or more of fluid conduits, refrigerant conduits, distribution conduits, or some combination thereof. Structure wall 104 may include one or more of dwelling or building structure walls, interior structure walls, exterior structure walls, ceilings, flooring, or some combination thereof.

In general, during installation of air conditioner unit 100, the indoor portion 106 is first mounted within an indoor atmosphere on an interior structure wall 104, e.g., using any suitable mechanical fastener, welding, adhesive, etc. In addition, the joint between the indoor portion 106 and interior structure wall 104 may be unsealed or sealed using any suitable caulk, sealant, etc. In general, during installation of air conditioner unit 100, the outdoor portion 108 is first mounted in an outdoor atmosphere on or near an exterior structure wall 104, e.g., using brackets, a stabilization pad, mechanical fastener, welding, adhesive, etc.

FIG. 2. provides a provides a schematic view of air conditioner unit 100. FIG. 3 and FIG. 4 provide front and rear sectional perspective views of outdoor portion 108 of air conditioner unit 100, respectively. FIG. 5 provides a front perspective view of the indoor portion of air conditioner unit 100. Referring now to generally FIGS. 1 through 5, as shown, sealed system 102 includes a compressor 130, an indoor heat exchanger or coil 132 and an outdoor heat exchanger or coil 134. As is generally understood, compressor 130 is generally operable to circulate or urge a flow of refrigerant through sealed system 102, which may include various conduits, e.g., refrigerant conduit 144, which may be utilized to flow refrigerant between the various components of sealed system 102. Thus, indoor heat exchanger 132 and outdoor heat exchanger 134 may be between and in fluid communication with each other and compressor 130.

As will be described in further detail below, sealed system 102 may operate in a cooling mode and, alternately, a heating mode. During operation of sealed system 102 in the cooling mode, refrigerant generally flows from indoor heat exchanger 132 and to compressor 130. During operation of sealed system 102 in the heating mode, refrigerant generally flows from outdoor heat exchanger 134 and to compressor 130. As will be explained in more detail below, a compression reversing valve 136 in fluid communication with compressor 130 may control refrigerant flow to and from compressor 130, as well as the indoor and outdoor coils 132, 134.

During operation of sealed system 102 in the cooling mode, refrigerant flows from indoor heat exchanger 132 and to compressor 130. For example, refrigerant may exit indoor heat exchanger 132 as a fluid in the form of a superheated vapor. Upon exiting indoor heat exchanger 132, the refrigerant may enter compressor 130, which is operable to compress the refrigerant. Also, generally an accumulator 122 is coupled to the compressor 130 to protect the compressor from liquid refrigerant and to store refrigerant until it is needed. Accordingly, the pressure and temperature of the refrigerant may be increased in compressor 130 such that the refrigerant becomes a more superheated vapor.

In general, among other components, indoor portion 106 includes indoor heat exchanger 132 and an indoor fan 146. In general, among other components, outdoor portion 108 includes outdoor heat exchanger 134, compressor 130, an expansion device or variable electronic expansion valve 142, and an outdoor fan 140. Outdoor heat exchanger 134 is disposed downstream of compressor 130 in the cooling mode and acts as a condenser. Thus, outdoor heat exchanger 134 is operable to reject heat into the exterior atmosphere at outdoor portion 108 when sealed system 102 is operating in the cooling mode. For example, the superheated vapor from compressor 130 may enter outdoor heat exchanger 134 via a first distribution conduit that extends between and fluidly connects compression reversing valve 136 and outdoor heat exchanger 134. Within outdoor heat exchanger 134, the refrigerant from compressor 130 transfers energy to the exterior atmosphere and condenses into a saturated liquid and/or liquid vapor mixture. An exterior air handler or outdoor fan 140 (FIG. 3) powered by a fan motor 162 is positioned adjacent to outdoor heat exchanger 134 and may facilitate or urge a flow of air from the exterior atmosphere across outdoor heat exchanger 134 in order to facilitate heat transfer. Generally, at least one refrigerant filter 148 is strategically placed, e.g., adjacent to the compressor 130 and/or adjacent to the variable electronic expansion valve 142, is present to remove contaminants from the refrigerant and keep the refrigerant conduit 144 clean.

According to the illustrated embodiment, an expansion device or a variable electronic expansion valve 142 may be further provided to regulate refrigerant expansion. Specifically, variable electronic expansion valve 142 is disposed along refrigerant conduit 144 that extends between indoor heat exchanger 132 and outdoor heat exchanger 134. During use, variable electronic expansion valve 142 may generally expand the refrigerant, lowering the pressure and temperature thereof. In the cooling mode, refrigerant, which may be in the form of high liquid quality/saturated liquid vapor mixture, may exit outdoor heat exchanger 134 and travel through variable electronic expansion valve 142 before flowing through indoor heat exchanger 132. In the heating mode, refrigerant may exit indoor heat exchanger 132 and travel through variable electronic expansion valve 142 before flowing to outdoor heat exchanger 134. As described in more detail below, variable electronic expansion valve 142 is generally configured to be adjustable. In other words, the flow (e.g., volumetric flow rate in milliliters per second) of refrigerant through variable electronic expansion valve 142 may be selectively varied or adjusted.

Indoor heat exchanger 132 is disposed downstream of variable electronic expansion valve 142 in the cooling mode and acts as an evaporator. Thus, indoor heat exchanger 132 is operable to heat refrigerant within indoor heat exchanger 132 with energy from the interior atmosphere at indoor portion 106 when sealed system 102 is operating in the cooling mode. For example, the liquid or liquid vapor mixture refrigerant from variable electronic expansion valve 142 may enter indoor heat exchanger 132 via refrigerant conduit 144. Within indoor heat exchanger 132, the refrigerant from variable electronic expansion valve 142 receives energy from the interior atmosphere and vaporizes into superheated vapor and/or high-quality vapor mixture. An interior air handler or indoor fan 146 powered by a fan motor (not shown) is positioned adjacent to indoor heat exchanger 132 and may facilitate or urge a flow of air from the interior atmosphere across indoor heat exchanger 132 in order to facilitate heat transfer. Additionally, a louver motor 128 may open, close, or move louvers within the indoor portion 106 to assist in regulating air flow and heat transfer. From indoor heat exchanger 132, refrigerant may return to compressor 130 from compression reversing valve 136, e.g., via a refrigerant conduit 144 that extends between and fluidly connects indoor heat exchanger 132 and compression reversing valve 136.

During operation of sealed system 102 in the heating mode, compression reversing valve 136 reverses the direction of refrigerant flow from compressor 130. Thus, in the heating mode, indoor heat exchanger 132 is disposed downstream of compressor 130 and acts as a condenser, e.g., such that indoor heat exchanger 132 is operable to reject heat into the interior atmosphere at indoor portion 106. In addition, outdoor heat exchanger 134 is disposed downstream of variable electronic expansion valve 142 in the heating mode and acts as an evaporator, e.g., such that outdoor heat exchanger 134 is operable to heat refrigerant within outdoor heat exchanger 134 with energy from the exterior atmosphere at outdoor portion 108.

Accordingly, as is understood in the art, sealed system 102 may be alternately operated as a refrigeration assembly (and thus perform a refrigeration cycle) or a heat pump (and thus perform a heat pump cycle). As shown in FIG. 2, when sealed system 102 is operating in a cooling mode and thus performing a refrigeration cycle, the indoor heat exchanger 132 acts as an evaporator and the outdoor heat exchanger 134 acts as a condenser. Alternatively, when the assembly is operating in a heating mode and thus performs a heat pump cycle, the indoor heat exchanger 132 acts as a condenser and the outdoor heat exchanger 134 acts as an evaporator. The indoor and outdoor heat exchangers 132, 134 may each include coils through which a refrigerant may flow for heat exchange purposes, as is generally understood.

In addition, sealed system 102 may be operated in a defrost mode, e.g., to remove frost from outdoor heat exchanger 134, particularly when the ambient temperature is low. In this regard, in the defrost mode, sealed system 102 is configured to urge hot refrigerant directly into outdoor heat exchanger, e.g., by adjusting the operation of compressor 130 and compressions reversing valve 136. This hot refrigerant causes any frozen condensate on the coils of outdoor heat exchanger to melt and fall off into base pan 120.

Generally, air conditioner unit 100 may additionally include a control panel 160 and one or more user inputs (not shown), which may be included in control panel 160. A display 164 (FIG. 1) may additionally be provided in the control panel 160, such as a touchscreen or other text-readable display screen. Alternatively, display 164 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 air conditioner unit 100. The user inputs (not shown) and/or display 164 may be in communication with a controller 166. A user of air conditioner unit 100 may interact with the user inputs (not shown) to operate air conditioner unit 100, and user commands may be transmitted between the user inputs (not shown) and controller 166 to facilitate operation of air conditioner unit 100 based on such user commands.

Controller 166 may regulate operation of air conditioner unit 100, e.g., responsive to sensed conditions and user input from control panel 160. Thus, controller 166 is operably coupled to various components of air conditioner unit 100, such as control panel 160, components of sealed system 102, a main control board 124, a module control board 126, and/or an ambient temperature sensor 170, such as a thermistor or thermocouple, for measuring the temperature of the interior atmosphere. In particular, controller 166 may selectively activate sealed system 102 in order to chill or heat air within sealed system 102, e.g., in response to temperature measurements from the ambient temperature sensor 170. To protect the components of air conditioner unit 100, a power factor reactor 168 may be present in air conditioner unit 100 to filter out harmonics and protect air conditioner unit 100 from surge voltage. Additionally, in an example embodiment, a plurality of terminal blocks 138 are present in both the indoor portion 106 and outdoor portion 108 respectively to separate signals without releasing connected conductors.

In order to facilitate operation of sealed system 102 and other components of air conditioner unit 100, air conditioner unit 100 may include a variety of sensors for detecting conditions internal and external to air conditioner unit 100. These conditions can be fed to controller 166 which may make decisions regarding operation of air conditioner unit 100. For example, as best illustrated in FIG. 2, air conditioner unit 100 may include an ambient temperature and/or humidity sensor 170 which is positioned and configured for measuring the outdoor or ambient temperature and/or humidity. According to exemplary embodiments, air conditioner unit 100 may further include an indoor temperature/humidity sensor for measuring indoor conditions temperatures.

As used herein, “temperature sensor” or the equivalent is intended to refer to any suitable type of temperature measuring system or device positioned at any suitable location for measuring the desired temperature. Thus, for example, ambient temperature sensor 170 may each be any suitable type of temperature sensor, such as a thermistor, a thermocouple, a resistance temperature detector, a semiconductor-based integrated circuit temperature sensor, etc. The same follows for defrost temperature sensor 172, discharge temperature sensor 174, suction line temperature sensor 176, and piping temperature sensor 178, all of which may be present on the air conditioner unit 100. In addition, ambient temperature sensor 170 may be positioned at any suitable location and may output a signal, such as a voltage, to a controller 166 that is proportional to and/or indicative of the temperature being measured. Although exemplary positioning of temperature sensors is described herein, it should be appreciated that air conditioner unit 100 may include any other suitable number, type, and position of temperature, and/or other sensors according to alternative embodiments.

As used herein, the terms “humidity sensor” or the equivalent may be intended to refer to any suitable type of humidity measuring system or device positioned at any suitable location for measuring the desired humidity. Thus, for example, humidity sensor 170 may refer to any suitable type of humidity sensor, such as capacitive digital sensors, resistive sensors, and thermal conductivity humidity sensors. In addition, humidity sensor 170 may be positioned at any suitable location and may output a signal, such as a voltage, to a controller that is proportional to and/or indicative of the humidity being measured. Although exemplary positioning of humidity sensors is described herein, it should be appreciated that unit 100 may include any other suitable number, type, and position of humidity sensors according to alternative embodiments.

In some embodiments, controller 166 includes memory and one or more processing devices. For instance, the processing devices may be 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 166 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 also generally to FIGS. 6 through 10, an angled mounting bracket 200 of air conditioner unit 100 will be described according to example embodiments of the present subject matter. In this regard, industry guidelines or government regulations generally establish requirements for refrigerant leak detection systems in certain air conditioner units having a refrigerant charge limit exceeding a set charge limit. Accordingly, air conditioner unit 100 may include a refrigerant leak sensor 240 to properly conform to industry guidelines or government regulations when the refrigerant charge limit calls for a refrigerant leak sensor 240. The angled mounting bracket 200 may include one or more features that facilitate the inclusion of the refrigerant leak sensor 240 in the air conditioner unit 100.

According to an example embodiment, angled mounting bracket 200 may include a first portion 202 of the angled mounting bracket 200 and a second portion 204 of the angled mounting bracket 200. The first portion 202 of the angled mounting bracket 200 defines, extends within, or is otherwise associated with a first plane, and the second portion 204 of the angled mounting bracket 200 defines, extends within, or is otherwise associated with a second plane. The angled mounting bracket 200 may further include a first mounting structure 210 defined by the first portion 202 of the angled mounting bracket 200 and a second mounting structure 220 defined by the second portion 204 of the angled mounting bracket 200. The first mounting structure 210 may be configured to receive an auxiliary component of the air conditioner unit 100, and the second mounting structure may be configured to receive the refrigerant leak sensor 240.

As best illustrated in FIG. 6, and FIG. 7, in one example embodiment, the angled mounting bracket 200 is located or positioned within the indoor portion 106 of the air conditioner unit 100. The first portion 202 of the angled mounting bracket 200 may be affixed to the indoor portion 106 air conditioner unit 100. The positioning of the angled mounting bracket 200 may be adjacent to the refrigerant conduit 144 and proximate to an access panel (not shown) located near a distal end of the indoor portion 106. The refrigerant leak sensor 240 may be coupled to the second mounting structure 220 of the second portion 204 of the angled mounting bracket 200. Furthermore, the first mounting structure 210 may be configured to receive an auxiliary component of the air conditioner unit 100, wherein the auxiliary component of the air conditioner unit 100 may include a strain relief assembly 230.

In this regard, the strain relief assembly 230 may be coupled to the first mounting structure 210 of the first portion 202 of the angled mounting bracket 200. In the air conditioner unit 100, a plurality of power wires 150 that lead to the plurality of terminal blocks 138 may be located within the indoor portion 106 and outdoor portion 108, respectively. The plurality of power wires 150 may be oriented so that a distal end of the power wires 150 located within the indoor portion 106 is positioned inside the strain relief assembly 230. In one example embodiment, the refrigerant leak sensor 240 coupled to the second portion 204 of the angled mounting bracket 200 may be oriented below a section of the refrigerant conduit 144 located within the indoor portion 106 of the air conditioner unit 100. For example, the refrigerant leak sensor 240 oriented below the section of the refrigerant conduit 144 allows the refrigerant leak sensor 240 to properly detect any potential leaks as refrigerant is heavier than air.

Notably, as best illustrated in FIGS. 8 through 10, according to an example embodiment, the first portion 202 of the angled mounting bracket 200 may include a plurality of fastening holes 208. In an example embodiment, the plurality of fastening holes 208 may include at least one locating hole which facilitates proper positioning of an intended mounting position when the first portion 202 of the angled mounting bracket 200 is affixed to the air conditioner unit 100. Additionally, the second portion 204 of the angled mounting bracket 200 may include at least one fastening hole 208. Fastening holes 208 may be threaded or non-threaded and configured to receive a mechanical fastener, e.g., a screw, bolt, clamp, etc., configured to attach the first portion 202 of the angled mounting bracket 200 to the air conditioner unit 100.

Accordingly, the angled mounting bracket 200 may further define an angle 250 between the second portion 204 of the angled mounting bracket 200 and the first portion 202 of the angled mounting bracket 200. According to example embodiments, the angle 250 is between 65 and 135 degrees. This range allows for limited flexibility of mounting options while appropriately accounting for the orientation of the second mounting structure 220 configured to receive the refrigerant leak sensor 240. In one example embodiment, the angle 250 is approximately 120 degrees to allow for proper second mounting structure 220 configured to receive the refrigerant leak sensor 240 orientation. In an alternative embodiment, the angle 250 is approximately 75 degrees to allow for proper second mounting structure 220 configured to receive the refrigerant leak sensor 240 orientation.

According to an example embodiment, the angled mounting bracket 200 may further include a plurality of flanges 206. The plurality of flanges 206 may be oriented along edges of the second portion 204 of the angled mounting bracket 200 adjacent to the angle 250. Further, the plurality flanges 206 may extend perpendicular to the second portion 204 of the angled mounting bracket 200. For example, the plurality of flanges 206 may be configured to prevent rotation of the refrigerant leak sensor 240 by limiting degrees of freedom movement about the fastening hole 208.

In another example embodiment, the first plane defining the first portion 202 of the angled mounting bracket 200 may extend along the vertical direction V, the second plane defining the second portion 204 of the angled mounting bracket 200 may extend along the lateral direction L. Furthermore, the first mounting structure 210 and second mounting structure 220 may extend along the transverse direction T of the angled mounting bracket 200.

According to alternative example embodiments, the at least one fastening hole 208 included on the second portion 204 of the angled mounting bracket 200 may only include one fastening hole 208. Furthermore, the plurality of fastening holes 208 included on the first portion 202 of the angled mounting bracket 200 may include one fastening hole 208 and one locating hole 208. For example, this fastening hole 208 may be used for attachment to the air conditioner unit 100, one locating hole 208 may be used to assist in correctly orienting the first portion 202 of the angled mounting bracket 200, and one fastening hole 208 included in the second portion 204 may be configured to receive the auxiliary component of the air conditioner unit 100, e.g., the strain relief assembly 230.

Now that construction of air conditioner unit 100 and the angled mounting bracket 200 according to exemplary embodiments have been presented, an exemplary method 300 of assembling an air conditioner unit will be described. Although the discussion below refers to the exemplary method 300 of constructing air conditioner unit 100, one skilled in the art will appreciate that the exemplary method 300 is applicable to a variety of other air conditioner appliances. In exemplary embodiments, the various method steps are disclosed herein may be performed in a manufacturing facility using known manufacturing methods, e.g., discrete manufacturing, repetitive manufacturing, batch process manufacturing, machining, additive manufacturing, etc.

As described in detail below, exemplary embodiments of the present subject matter may involve the use of additive manufacturing machines or methods. As used herein, the terms “additively manufactured” or “additive manufacturing techniques or processes” refer generally to manufacturing processes wherein successive layers of material(s) are provided on each other to “build-up,” layer-by-layer, a three-dimensional component. The successive layers generally fuse together to form a monolithic component which may have a variety of integral sub-components.

Although additive manufacturing technology is described herein as enabling fabrication of complex objects by building objects point-by-point, layer-by-layer, typically in a vertical direction, other methods of fabrication are possible and within the scope of the present subject matter. For example, although the discussion herein refers to the addition of material to form successive layers, one skilled in the art will appreciate that the methods and structures disclosed herein may be practiced with any additive manufacturing technique or manufacturing technology. For example, embodiments of the present invention may use layer-additive processes, layer-subtractive processes, or hybrid processes.

Suitable additive manufacturing techniques in accordance with the present disclosure include, for example, Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), 3D printing such as by inkjets and laserjets, Sterolithography (SLA), Direct Selective Laser Sintering (DSLS), Electron Beam Sintering (EBS), Electron Beam Melting (EBM), Laser Engineered Net Shaping (LENS), Laser Net Shape Manufacturing (LNSM), Direct Metal Deposition (DMD), Digital Light Processing (DLP), Direct Selective Laser Melting (DSLM), Selective Laser Melting (SLM), Direct Metal Laser Melting (DMLM), and other known processes.

In addition to using a direct metal laser sintering (DMLS) or direct metal laser melting (DMLM) process where an energy source is used to selectively sinter or melt portions of a layer of powder, it should be appreciated that according to alternative embodiments, the additive manufacturing process may be a “binder jetting” process. In this regard, binder jetting involves successively depositing layers of additive powder in a similar manner as described above. However, instead of using an energy source to generate an energy beam to selectively melt or fuse the additive powders, binder jetting involves selectively depositing a liquid binding agent onto each layer of powder. The liquid binding agent may be, for example, a photo-curable polymer or another liquid bonding agent. Other suitable additive manufacturing methods and variants are intended to be within the scope of the present subject matter.

The additive manufacturing processes described herein may be used for forming components using any suitable material. For example, the material may be plastic, metal, concrete, ceramic, polymer, epoxy, photopolymer resin, or any other suitable material that may be in solid, liquid, powder, sheet material, wire, or any other suitable form. More specifically, according to exemplary embodiments of the present subject matter, the additively manufactured components described herein may be formed in part, in whole, or in some combination of materials including but not limited to plastics, pure metals, metal alloys (e.g., such as nickel, chrome, titanium, iron, stainless steel, etc.), epoxy, composites, or any other suitable polymer, ceramic, or metal materials. These materials are examples of materials suitable for use in the additive manufacturing processes described herein and may be generally referred to as “additive materials.”

In addition, one skilled in the art will appreciate that a variety of materials and methods for bonding those materials may be used and are contemplated as within the scope of the present disclosure. As used herein, references to “fusing” may refer to any suitable process for creating a bonded layer of any of the above materials. For example, if an object is made from polymer, fusing may refer to creating a thermoset bond between polymer materials. If the object is epoxy, the bond may be formed by a crosslinking process. If the material is ceramic, the bond may be formed by a sintering process. If the material is powdered metal, the bond may be formed by a melting or sintering process. One skilled in the art will appreciate that other methods of fusing materials to make a component by additive manufacturing are possible, and the presently disclosed subject matter may be practiced with those methods.

In addition, the additive manufacturing process disclosed herein allows a single component to be formed from multiple materials. Thus, the components described herein may be formed from any suitable mixtures of the above materials. For example, a component may include multiple layers, segments, or parts that are formed using different materials, processes, and/or on different additive manufacturing machines. In this manner, components may be constructed which have different materials and material properties for meeting the demands of any particular application. In addition, although the components described herein are constructed entirely by additive manufacturing processes, it should be appreciated that in alternate embodiments, all or a portion of these components may be formed via casting, machining, and/or any other suitable manufacturing process. Indeed, any suitable combination of materials and manufacturing methods may be used to form these components.

An exemplary additive manufacturing process will now be described. Additive manufacturing processes fabricate components using three-dimensional (3D) information, for example a three-dimensional computer model, of the component. Accordingly, a three-dimensional design model of the component may be defined prior to manufacturing. In this regard, a model or prototype of the component may be scanned to determine the three-dimensional information of the component. As another example, a model of the component may be constructed using a suitable computer aided design (CAD) program to define the three-dimensional design model of the component.

The design model may include 3D numeric coordinates of the entire configuration of the component including both external and internal surfaces of the component. For example, the design model may define the body, the surface, and/or internal passageways such as openings, support structures, etc. In one exemplary embodiment, the three-dimensional design model is converted into a plurality of slices or segments, e.g., along a central (e.g., vertical) axis of the component or any other suitable axis. Each slice may define a thin cross section of the component for a predetermined height of the slice. The plurality of successive cross-sectional slices together form the 3D component. The component is then “built-up” slice-by-slice, or layer-by-layer, until finished.

In this manner, the components described herein may be fabricated using the additive process, or more specifically each layer is successively formed, e.g., by fusing or polymerizing a plastic using laser energy or heat or by sintering or melting metal powder. For example, a particular type of additive manufacturing process may use an energy beam, for example, an electron beam or electromagnetic radiation such as a laser beam, to sinter or melt a powder material. Any suitable laser and laser parameters may be used, including considerations with respect to power, laser beam spot size, and scanning velocity. The build material may be formed by any suitable powder or material selected for enhanced strength, durability, and useful life, particularly at high temperatures.

Each successive layer may be, for example, between about 10 μm and 200 μm, although the thickness may be selected based on any number of parameters and may be any suitable size according to alternative embodiments. Therefore, utilizing the additive formation methods described above, the components described herein may have cross sections as thin as one thickness of an associated powder layer, e.g., 10 μm, utilized during the additive formation process.

In addition, utilizing an additive process, the surface finish and features of the components may vary as need depending on the application. For example, the surface finish may be adjusted (e.g., made smoother or rougher) by selecting appropriate laser scan parameters (e.g., laser power, scan speed, laser focal spot size, etc.) during the additive process, especially in the periphery of a cross-sectional layer which corresponds to the part surface. For example, a rougher finish may be achieved by increasing laser scan speed or decreasing the size of the melt pool formed, and a smoother finish may be achieved by decreasing laser scan speed or increasing the size of the melt pool formed. The scanning pattern and/or laser power can also be changed to change the surface finish in a selected area.

Notably, in exemplary embodiments, several features of the components described herein were previously not possible due to manufacturing restraints. However, the present inventors have advantageously utilized current advances in additive manufacturing techniques to develop exemplary embodiments of such components generally in accordance with the present disclosure. While the present disclosure is not limited to the use of additive manufacturing to form these components generally, additive manufacturing does provide a variety of manufacturing advantages, including ease of manufacturing, reduced cost, greater accuracy, etc.

In this regard, utilizing additive manufacturing methods, even multi-part components may be formed as a single piece of continuous metal, polymer, or other desired material, and may thus include fewer sub-components and/or joints compared to prior designs. The integral formation of these multi-part components through additive manufacturing may advantageously improve the overall assembly process. For example, the integral formation reduces the number of separate parts that must be assembled, thus reducing associated time and overall assembly costs. Additionally, existing issues with, for example, leakage, joint quality between separate parts, and overall performance may advantageously be reduced.

Also, the additive manufacturing methods described above enable much more complex and intricate shapes and contours of the components described herein. For example, such components may include thin additively manufactured layers and features in the finished component. In addition, the additive manufacturing process enables the manufacture of a single component having different materials such that different portions of the component may exhibit different performance characteristics. The successive, additive nature of the manufacturing process enables the construction of these novel features. As a result, the components described herein may exhibit improved performance and reliability.

Referring to FIG. 11, method 300 includes, at 310, affixing a strain relief assembly to the first mounting structure of the first portion of the angled mounting bracket. As explained above, using air conditioner unit 100 as an example, the strain relief assembly 230 may be affixed by any suitable mechanical fastener, welding, adhesive, etc. This may be done with any manufacturing method well known in the art. In addition, the strain relief assembly 230 may be configured to receive a distal end of the plurality of power wires 150 located within the indoor portion is positioned inside the strain relief assembly 230.

Method 300 further includes, at step 320, coupling a refrigerant leak sensor to the second mounting structure of the second portion of the angled mounting bracket. As explained above, and again using air conditioner unit 100 as an example, a refrigerant leak sensor 240 coupled to the second mounting structure 220 of the second portion 204 of the angled mounting bracket 200. The appropriate orientation of the refrigerant leak sensor 240 and the strain relief assembly 230 is enabled by the angle 250 present in the angled mounting bracket 200.

Method 300 further includes, at step 330, affixing the first portion of the angled mounting bracket to the air conditioner unit positioned proximate to an access panel located near a distal end of the indoor portion. As explained above, and again using air conditioner unit 100 as an example, the angled mounting bracket 200 may be positioned in the air conditioner unit 100, and attached thereto, positioned proximate to an access panel located near a distal end of the indoor portion 106 to increase accessibility to the angled mounting bracket 200.

FIG. 11 depicts steps performed in a particular order for purposes of illustration and discussion. Those of ordinary skill in the art, using the disclosures provided herein, will understand that the steps of any of the methods discussed herein can be adapted, rearranged, expanded, omitted, or modified in various ways without deviating from the scope of the present disclosure. Moreover, although aspects of method 300 are explained using unit 100 as an example, it should be appreciated that this method may be applied to assemble an angled mounting bracket 200 for any suitable 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.