DEVICE FOR COLLECTING REFRIGERANT LEAKING FROM AN APPLIANCE

Abstract

A heating, ventilation, and air conditioning system including a heat exchanger assembly and a refrigerant collection device. The refrigerant collection device has a body axially aligned with a perimeter of the heat exchanger assembly. The body has at least one channel formed therein to capture a refrigerant and direct the captured refrigerant to a detection location of the body.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/240,521 filed Sep. 3, 2021, the disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND

Exemplary embodiments of the present disclosure relate to heating, ventilation, and air conditioning (HVAC) systems, and more particularly, to a device for use with a HVAC system to facilitate detection and safe mitigation of a refrigerant leak.

Refrigeration systems, as used in HVAC applications, utilize refrigerant within a closed loop circuit to condition air provided to an area or enclosed space. This refrigerant, historically, has been provided as a fluid with a high global warming potential (GWP) value such as R134A or R410A. Thus, although the refrigerants that have been used previously are effective coolants, the negative effect they can have on the environment has led to regulatory requirements to transition to refrigerants which have moderate-to-low GWP values.

Modem refrigerants, for example A2L refrigerants, comply with environmental regulations relating to global warming potential (GWP). In order to comply with the proposed GWP regulations, hydrofluorocarbon (HFC) and hydrocarbon refrigerants with various levels of flammability are being developed and are being considered for use in HVAC systems.

As with any system, there is a potential for flammable refrigerants used in 1-IVAC applications to leak and migrate to undesirable areas in the vicinity of the HVAC system that may contain an ignition source. When the flammable refrigerants, in the presence of air or another oxidizer, are exposed to an ignition source, the potential for a combustion event exists.

BRIEF DESCRIPTION

According to an embodiment, a heating, ventilation, and air conditioning system including a heat exchanger assembly and a refrigerant collection device. The refrigerant collection device has a body axially aligned with a perimeter of the heat exchanger assembly. The body has at least one channel formed therein to capture a refrigerant and direct the captured refrigerant to a detection location of the body.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments the body has a generally horizontal configuration relative to the heat exchanger assembly.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments the body has a generally sloped configuration relative to the heat exchanger assembly.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments the at least one channel having a base and at least one sidewall extending at an angle from the base.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments a configuration of the at least one channel varies about the body of the refrigerant collection device.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments the at least one sidewall includes an inward sidewall and an outward sidewall arranged at opposite sides of the base.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments the outward sidewall is formed by another component of the HVAC system.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments a height of the inward sidewall is different than a height of the outward sidewall.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments the at least one channel includes a front portion, a back portion, and a side portion fluidly connecting the front portion and the back portion.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments comprising at least one cross-piece extending between and fluidly connected to the front portion and the back portion of the at least one channel.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments the at least one cross-piece has a V-shape.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments the at least one cross-piece is vertically offset from the base of the at least one channel.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments the heat exchanger assembly further comprises a tube bank and the at least one cross-piece is axially aligned with a central portion of the tube bank.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments the heat exchanger assembly further comprises a condensate drain pan and the body of the refrigerant collection device is coupled to the condensate drain pan.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments the heat exchanger assembly further comprises a condensate drain pan and the body of the refrigerant collection device is integrally formed with the condensate drain pan.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments the heat exchanger assembly includes an apex and the body of the refrigerant collection device includes a plurality of cutouts, the apex being receivable within the plurality of cutouts.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments the body of the refrigerant collection device is formed from a plurality of separate pieces.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments the heat exchanger assembly includes an apex, and the plurality of separate pieces includes a first piece and a second piece, the first piece extending from the apex in a first direction and the second piece extending from the apex in a second, opposite direction.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments the second piece is a mirror image of the first piece.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments comprising a detection sensor mounted to the refrigerant collection device adjacent to the detection location.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:

FIG. 1 is a schematic diagram of an exemplary HVAC system, depicted as a furnace coil or fan coil unit, according to an embodiment;

FIG. 2 is a perspective view of an exemplary refrigerant collection device for use in a HVAC system, such as a furnace coil or fan coil unit, according to an embodiment;

FIG. 3 is a perspective view of an exemplary refrigerant collection device for use in a HVAC system, such as a furnace coil or fan coil unit, according to an embodiment;

FIG. 4 is a perspective view of another exemplary refrigerant collection device for use in a HVAC system, such as a furnace coil or fan coil unit, according to an embodiment;

FIG. 5 is a perspective view of yet another exemplary refrigerant collection device for use in a HVAC system, such as a furnace coil or fan coil unit, according to an embodiment; and

FIG. 6 is a perspective view of a refrigerant collection device installed within a furnace coil or fan coil unit according to an embodiment.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.

With reference now to FIG. 1, an example of a heating, ventilation, and air conditioning (HVAC) system 20 is illustrated, depicted as a furnace coil or fan coil unit 20. Although described herein as furnace or fan coil unit it should be appreciated that the HVAC; system 20 may be any heating or cooling system. As shown, the furnace coil or fan coil unit 20 includes a cabinet or housing duct 22 within which various components of the HVAC system are located. For example, housed within the cabinet 22 of the furnace coil or fan coil unit 20 is a heat exchanger assembly 24 configured to heat and/or cool the adjacent air. A blower or fan assembly 26 may also be arranged within the cabinet 22 or alternatively, at a position outside of but in fluid communication with the cabinet 22. The blower 26 is operable to circulate a flow of air A through the interior of the cabinet 22, across the heat exchanger assembly 24. Depending on the desired characteristics of the furnace coil or fan coil unit 20, the blower 26 may be positioned either downstream with respect to the heat exchanger assembly 24 (i.e., a “draw through” configuration), or upstream with respect to the heat exchanger assembly 24 (i.e., a “blow through” configuration), as shown in FIG. 1.

The heat exchanger assembly 24 may include any of a plurality of configurations. As illustrated in FIG. 1, the heat exchanger assembly 24 includes one or more heat exchanger coils 28 arranged in a non-linear configuration. For example, the heat exchanger assembly 24 may have a generally V-shaped configuration, a generally A-shaped configuration, or a generally N-shaped configuration, as is known in the art. In other embodiments, the heat exchanger assembly 24 may include a single heat exchanger coil 28 arranged at an angle with respect to the flow path of air A through the cabinet 22. In embodiments where the furnace coil or fan coil unit 20 is configured to provide cool air, the heat exchanger assembly 24 absorbs heat from the air A passing through the heat exchanger assembly 24 and the resultant cool air A is provided to a space to be conditioned.

As shown, the furnace coil or fan coil unit 20 typically includes a condensate drain pan 30 arranged adjacent to the heat exchanger assembly 24 within the cabinet 22, such as at the lower side of the heat exchanger assembly 24 for example. As the air A flowing through the heat exchanger assembly 24 is cooled, a portion of the water within the flow of air A may condense and collect on the surfaces of the heat exchanger coil(s) 28. Gravity and continued air flow through the heat exchanger assembly 24 may cause a portion of this condensation to fall from the heat exchanger assembly 24 onto the drain pain 30.

With continued reference to FIG. 1, the refrigerant circulating within the heat exchanger assembly 24 may, in rare instances, leak. When utilizing A2L refrigerants, a leak of refrigerant could lead to undesirable consequences due to the mildly flammable nature of A2L refrigerants. Accordingly, the furnace coil or fan coil unit 20 may include at least one detection sensor or assembly 32 operable to detect a refrigerant leak therein. Examples of the detection sensor or assembly 32 include, but are not limited to a point sensor and a line of sight or beam sensor. Further, the technologies used by one or more detection sensors may include non-dispersive infrared (NDIR), photoacoustic spectroscopy (PAS), quantum cascade laser spectroscopy (QCLS), tunable diode laser spectroscopy (TDLS), thermal conductivity (TC), metal oxide semiconductor (MOS), ultrasonic, speed of sound, and ultraviolet spectroscopy for example. However, it should be understood that any suitable type of detection sensor or assembly 32 is within the scope of the disclosure.

In an embodiment, a refrigerant collection device 40 is located within the cabinet 22, adjacent to the heat exchanger assembly 24, and the one or more detection sensors 32 are mounted at or directly adjacent to a portion of the refrigerant collection device 40. With reference now to FIGS. 2-6, various examples of a refrigerant collection device 40 intended to capture refrigerant and direct an adequate amount of refrigerant to a detection location as it leaks from the heat exchanger assembly 24 are illustrated in more detail. In each of the illustrated, non-limiting embodiments, the refrigerant collection device 40 is shown as being located adjacent to an inner periphery of the cabinet 22, in axial alignment with a perimeter or periphery of the heat exchanger assembly 24. The refrigerant collection device 40 has a substantially hollow interior 41 to minimize interference with the flow through the furnace coil or fan coil unit, and more specifically, the heat exchanger assembly 24. In each of the illustrated embodiments, the refrigerant collection device 40 is configured to wrap about the entire inner periphery of the cabinet 22 (i.e., across the front 22a, back 22b and two sides 22c, 22d thereof). However, it should be understood that embodiments where the refrigerant collection device 40 extends about only a portion of the perimeter of the heat exchanger assembly 24 and/or the inner periphery of the cabinet 22 are also within the scope of the disclosure.

The refrigerant collection device 40 may be formed as a single component, as shown in FIGS. 2-4. When formed as a single component, the body 42 of the refrigerant collection device 40 may have one or more cutouts 44 formed therein complementary to a portion of the heat exchanger assembly 24. In the illustrated, non-limiting embodiments of FIGS. 2 and 4, the plurality of cutouts 44 formed in the refrigerant collection device 40 are axially aligned with one another and are generally complementary to the contour of the apex 25, such as formed by a bend or header for example, of the heat exchanger assembly 24. Accordingly, when the refrigerant collection device 40 is installed within the cabinet, the apex 25 of the heat exchanger assembly 24 may be positioned therein.

In other embodiments, the body 42 refrigerant collection device 40 may be formed by a plurality of pieces. In the non-limiting embodiment of FIG. 5, the refrigerant collection device 40 includes a first piece 42a and a second piece 42b, the first piece 42a and the second piece 42b being disposed at opposite sides of the heat exchanger assembly 24. In such embodiments, the first piece 42a may extend in a first direction from the apex 25 of the heat exchanger assembly, and the second piece 42b may extend from the apex 25 in a second direction. In such embodiments, the first piece 42a and the second piece 42b may be substantially identical, or alternatively, the first piece 42a may be a mirror image of the second piece 42b. Further, the first piece 42a and the second piece 42b may be separated or offset from one another when mounted within the cabinet 22 (FIG. 5), or alternatively, may be configured to couple to or overlap with one another. It should be understood that configurations of the refrigerant collection device 40 having any number of pieces 42, such as more than two pieces for example, having similar or different configurations, are also within the scope of the disclosure.

As shown, the body 42 or one or more of the pieces 42a, 42b that form the body of the refrigerant collection device 40 includes at least one channel 50 within which refrigerant leaking from the heat exchanger assembly 24 is collected and directed. In some embodiments, the body 42 or pieces thereof, have a plurality of channels for collecting refrigerant. In other embodiments, the body 42 or pieces 42a, 42b may each have a single channel 50 that extends continuously about each of the sides of the body 42 or respective pieces 42a, 42b of the refrigerant collection device 40. Accordingly, channel 50 of the refrigerant collection device 40 may have a front portion 50a, a back portion 50b, and one or more side portions 50c, each of which may be configured to fluidly connect the front portion 50a and the back portion 50b. The channel 50 typically has a base 52, for example oriented at an angle to one of the sides of the cabinet 22, and at least one sidewall extending at an angle from the base 52. In an embodiment, the channel 50 includes both an inward sidewall 54 and an outward sidewall 56 arranged at opposite sides of the base 52. The inward sidewall 54 and the outward sidewall 56 may be arranged generally parallel to one another, or alternatively, may be arranged at a non-zero angle to one another.

In the illustrated, non-limiting embodiment, the base 52 of each portion 50a-50c of the channel 50 is arranged within the same plane. However, it should be understood that embodiments where the orientation of the channel 50 varies are also contemplated herein. For example, the base 52 of one or more of the portions 50a-50c of the channels 50 may be slanted relative to a horizontal plane, for example to facilitate the flow of the liquid within the channel to a desired location within the channel 50.

The inward sidewall 54, base 52, and outward sidewall 56 of a portion 50a-50c of the channel 50 may be integrally formed, such as by bending a piece of sheet metal for example. However, embodiments where the inward sidewall 54, outward sidewall 56, and base 52 are not integrally formed are also contemplated herein. Further, embodiments where at least a portion of the refrigerant collection device 40, such as the outward sidewall 56 of at least a portion of the channel 50 for example, is formed by another component of the furnace coil or fan coil unit 20, such as a wall 22a-22d of the cabinet 22, or a portion of the condensate drain pan 30 for example, are also within the scope of the disclosure.

The width of the channel 50, measured as the width of the base 52 extending between the inward sidewall 54 and the outward sidewall 56 at a location, may be substantially constant about the body or respective pieces 42 of the refrigerant collection device 40, or alternatively, may vary. For example, a width of the front portion 50a of the channel 50 may be greater than the width of the back portion 50b of the channel 50. However, it should be understood that this variation may depend on the position of the one or more detection sensors 32 relative to the refrigerant collection device 40 to facilitate the flow of captured refrigerant within the channel 50 toward a detection location containing or adjacent to the one or more detection sensors 32. Further, a height of at least one of the inward sidewall 54 and the outward sidewall 56 may be substantially constant about the perimeter of the channel 50. However, in other embodiments best shown in FIG. 4, a height of one or both of the inward sidewall 54 and the outward sidewall 56 may vary about the perimeter of the channel 50. For example, the height of the inward sidewall 54 may gradually decrease towards the corners of the channel 50.

In the illustrated, non-limiting embodiment, a maximum height of the inward sidewall 54 relative to the base 52, measured parallel to the longitudinal axis of the cabinet 22 and the direction of air flow A through the cabinet 22, is greater than the maximum height of the outward sidewall 56 relative to the base 52. In other embodiments, however, the maximum height of the inward sidewall 54 may be less than or equal to the maximum height of the outward sidewall 56.

With reference to FIGS. 2 and 3, the refrigerant collection device 40 may additionally include at least one cross-piece 60. In the illustrated, non-limiting embodiment, the at least one cross-piece 60 extends between an opening 61 formed in the inward sidewall 54 at the back portion of the channel 50 and an opening 61 formed in the inward sidewall 54 at the front portion 50a of the channel 50. The at least one cross-piece 60 is illustrated as being arranged generally parallel to the adjacent sides 22c, 22d of the cabinet 22 and the side portion 50c of the channel 50; however, embodiments where the at least one cross-piece 60 is arranged at an angle to one or both the side 22c, 22d of the cabinet 22 and the side portion 50c of the channel 50 are within the scope of the disclosure. Further, although the at least one cross-piece 60 is shown as being generally centrally located between the apex 25 of the heat exchanger assembly 24 and the inward sidewall 54 of the side portion 50c of the channel 50, axially aligned with a central portion of the tube bank of the heat exchanger assembly 24, embodiments where at least one cross-piece 60 is skewed towards either the apex 25 or towards the inward sidewall 54 of the side portion of the channel 50 are contemplated herein.

The at least one cross-piece 60 may similarly have a cavity 62 or channel-like configuration. In the illustrated, non-limiting embodiment, the at least one cross-piece has a generally V-shaped configuration. By using a V-shape, the interference of the cross-piece with the air flow A through the cabinet 22 is minimized; however, any suitable shape defining a cavity 62 for receiving refrigerant is within the scope of the disclosure. Further, the at least one cross-piece 60 is arranged in fluid communication with one or both of the front portion 50a and the back portion 50b of the channel 50. To facilitate the flow of refrigerant from the cross-piece 60 to either the front portion 50a and the back portion 50b of the channel 50, the bottom of the cross-piece 60 may be elevated relative to the base 52 of the channel 50. Alternatively, or in addition, the at least one cross-piece 60 may have a generally horizontal configuration as shown, or may be angled relative to one or both the front portion 50a and the back portion 50b of the channel 50. For example, the height of the opening 61 formed in the inward sidewall 54 at the back portion 50b of the channel 50 may be greater than the height of the opening 61 formed in the inward sidewall 54 at the front portion 50a of the channel 50 such that the cross-piece 60 is sloped downwardly towards the front portion 50a of the channel 50. In other embodiments, the center of the cross-piece 60 may be higher than the ends of the cross-piece 60 such that the cross-piece 60 is sloped downwardly towards both the front portion 50a and the back portion 50b.

When the refrigerant collection device 40 is mounted within the cabinet 22, the base 52 of the channel 50, or at least a portion thereof, may have a generally horizontal configuration. However, in other embodiments, the refrigerant collection device may be mounted with a generally sloped configuration such that any liquid collected within the channel 50 is configured to flow in a desired manner via gravity. Further, although the refrigerant collection device is illustrated as being at generally the same vertical height as the condensate drain pan 30, embodiments where the refrigerant collection device 40 is vertically offset from the condensate drain pan 30 are also within the scope of the disclosure.

A refrigerant collection device 40 as described herein is configured to capture an adequate amount of leaking refrigerant as it falls from any location of the heat exchanger assembly 24 and in any direction therefrom and direct the collected refrigerant towards the detection sensor for enhanced leak detection. The refrigerant collection device 40 may further be designed to position the detection sensors 32 at a location that is easily accessible by field technicians. Further, in embodiments where the furnace coil or fan coil unit 20 is arranged adjacent to a furnace, the refrigerant collection device 40 additionally provides a protective barrier for shielding electronics from the heat emitted from the furnace heat exchanger.

The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.

While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.

Claims

1. A heating, ventilation, and air conditioning (HVAC) system comprising:

a heat exchanger assembly;

a refrigerant collection device having a body axially aligned with a perimeter of the heat exchanger assembly, the body having at least one channel formed therein to capture a refrigerant, wherein the body is configured to direct captured refrigerant to a detection location of the body.

2. The HVAC system of claim 1, wherein the body has a generally horizontal configuration relative to the heat exchanger assembly.

3. The HVAC system of claim 1, wherein the body has a generally sloped configuration relative to the heat exchanger assembly.

4. The HVAC system of claim 1, wherein the at least one channel having a base and at least one sidewall extending at an angle from the base.

5. The HVAC system of claim 4, wherein a configuration of the at least one channel varies about the body of the refrigerant collection device.

6. The HVAC system of claim 4, wherein the at least one sidewall includes an inward sidewall and an outward sidewall arranged at opposite sides of the base.

7. The HVAC system of claim 6, wherein the outward sidewall is formed by another component of the HVAC system.

8. The HVAC system of claim 6, wherein a height of the inward sidewall is different than a height of the outward sidewall.

9. The HVAC system of claim 4, wherein the at least one channel includes a front portion, a back portion, and a side portion fluidly connecting the front portion and the back portion.

10. The HVAC system of claim 9, further comprising at least one cross piece extending between and fluidly connected to the front portion and the back portion of the at least one channel.

11. The HVAC system of claim 10, wherein the at least one cross-piece has a V-shape.

12. The HVAC system of claim 10, wherein the at least one cross-piece is vertically offset from the base of the at least one channel.

13. The HVAC system of claim 10, wherein the heat exchanger assembly further comprises a tube bank and the at least one cross-piece is axially aligned with a central portion of the tube bank.

14. The HVAC system of claim 1, wherein the heat exchanger assembly further comprises a condensate drain pan and the body of the refrigerant collection device is coupled to the condensate drain pan.

15. The HVAC system of claim 1, wherein the heat exchanger assembly further comprises a condensate drain pan and the body of the refrigerant collection device is integrally formed with the condensate drain pan.

16. The HVAC system of claim 1, wherein the heat exchanger assembly includes an apex and the body of the refrigerant collection device includes a plurality of cutouts, the apex being receivable within the plurality of cutouts.

17. The HVAC system of claim 1, wherein the body of the refrigerant collection device is formed from a plurality of separate pieces.

18. The HVAC system of claim 17, wherein the heat exchanger assembly includes an apex, and the plurality of separate pieces includes a first piece and a second piece, the first piece extending from the apex in a first direction and the second piece extending from the apex in a second, opposite direction.

19. The HVAC system of claim 18, wherein the second piece is a mirror image of the first piece.

20. The HVAC system of claim 1, further comprising a detection sensor mounted to the refrigerant collection device adjacent to the detection location.