Condensate management system for an air conditioner appliance

Abstract

A condensate management system for an air conditioner unit, the air conditioner unit including a bulkhead mounted within a cabinet to define an indoor portion and an outdoor portion, an indoor heat exchanger positioned within the indoor portion, and an outdoor heat exchanger positioned within the outdoor portion. The condensate management system includes a base pan positioned under the outdoor heat exchanger for collecting condensate that drips off the outdoor heat exchanger, wherein a pan hole is defined through the base pan, a thermostatic drain valve operably coupled to the pan hole for selectively allowing the collected condensate to flow through the pan hole, and a heating element thermally coupled to the thermostatic drain valve for selectively heating the thermostatic drain valve.

What is claimed is: 
     
         1 . An air conditioner unit defining a vertical, a lateral, and a transverse direction, the air conditioner unit comprising:
 a bulkhead mounted within a cabinet to define an indoor portion and an outdoor portion;   an indoor heat exchanger positioned within the indoor portion;   an outdoor heat exchanger positioned within the outdoor portion;   a base pan positioned under the outdoor heat exchanger for collecting condensate that drips off the outdoor heat exchanger, wherein a pan hole is defined through the base pan; and   a drain assembly comprising:
 a thermostatic drain valve operably coupled to the pan hole for selectively allowing the collected condensate to flow through the pan hole; and 
 a heating element thermally coupled to the thermostatic drain valve for selectively heating the thermostatic drain valve. 
   
     
     
         2 . The air conditioner unit of  claim 1 , further comprising a temperature sensor and a controller in operative communication with the heating element and the temperature sensor, the controller being configured to:
 obtain an ambient temperature using the temperature sensor;   determine that the ambient temperature is above a higher temperature threshold; and   deactivate the heating element to permit the thermostatic drain valve to remain in a closed position in response to determining that the ambient temperature is above the higher temperature threshold.   
     
     
         3 . The air conditioner unit of  claim 1 , further comprising a temperature sensor and a controller in operative communication with the heating element and the temperature sensor, the controller being configured to:
 obtain an ambient temperature using the temperature sensor;   determine that the ambient temperature is between a lower temperature threshold and a higher temperature threshold; and   deactivate the heating element to permit the thermostatic drain valve to remain in an open position in response to determining that the ambient temperature is between the lower temperature threshold and the higher temperature threshold.   
     
     
         4 . The air conditioner unit of  claim 3 , wherein the higher temperature threshold is 32° Fahrenheit. 
     
     
         5 . The air conditioner unit of  claim 1 , further comprising a temperature sensor and a controller in operative communication with the heating element and the temperature sensor, the controller being configured to:
 obtain an ambient temperature using the temperature sensor;   determine that the ambient temperature is below a lower temperature threshold; and   operate the heating element to heat the thermostatic drain valve in response to determining that the ambient temperature is below the lower temperature threshold.   
     
     
         6 . The air conditioner unit of  claim 5 , wherein the lower temperature threshold is between 10° Fahrenheit and 30° Fahrenheit. 
     
     
         7 . The air conditioner unit of  claim 1 , further comprising a controller in operative communication with the heating element, the controller being configured to:
 activate the heating element;   perform a defrost cycle; and   turn off the heating element a predetermined amount of time after completing the defrost cycle.   
     
     
         8 . The air conditioner unit of  claim 7 , wherein the predetermined amount of time is between 30 minutes and 120 minutes. 
     
     
         9 . The air conditioner unit of  claim 1 , wherein the heating element is positioned in direct contact with the thermostatic drain valve. 
     
     
         10 . The air conditioner unit of  claim 1 , wherein the heating element is a metal or ceramic resistive cartridge heater. 
     
     
         11 . The air conditioner unit of  claim 1 , wherein the heating element engages the thermostatic drain valve through brazing or a thermal paste. 
     
     
         12 . The air conditioner unit of  claim 1 , wherein the air conditioner unit is a single-package vertical unit (SPVU) or a package terminal air conditioner (PTAC). 
     
     
         13 . A condensate management system for an air conditioner unit, the air conditioner unit comprising a bulkhead mounted within a cabinet to define an indoor portion and an outdoor portion, an indoor heat exchanger positioned within the indoor portion, and an outdoor heat exchanger positioned within the outdoor portion, the condensate management system comprising:
 a base pan positioned under the outdoor heat exchanger for collecting condensate that drips off the outdoor heat exchanger, wherein a pan hole is defined through the base pan;   a thermostatic drain valve operably coupled to the pan hole for selectively allowing the collected condensate to flow through the pan hole; and   a heating element thermally coupled to the thermostatic drain valve for selectively heating the thermostatic drain valve.   
     
     
         14 . The condensate management system of  claim 13 , further comprising a temperature sensor and a controller in operative communication with the heating element and the temperature sensor, the controller being configured to:
 obtain an ambient temperature using the temperature sensor;   determine that the ambient temperature is above a higher temperature threshold; and   deactivate the heating element to permit the thermostatic drain valve to remain in a closed position in response to determining that the ambient temperature is above the higher temperature threshold.   
     
     
         15 . The condensate management system of  claim 13 , further comprising a temperature sensor and a controller in operative communication with the heating element and the temperature sensor, the controller being configured to:
 obtain an ambient temperature using the temperature sensor;   determine that the ambient temperature is between a lower temperature threshold and a higher temperature threshold; and   deactivate the heating element to permit the thermostatic drain valve to remain in an open position in response to determining that the ambient temperature is between the lower temperature threshold and the higher temperature threshold.   
     
     
         16 . The condensate management system of  claim 13 , further comprising a temperature sensor and a controller in operative communication with the heating element and the temperature sensor, the controller being configured to:
 obtain an ambient temperature using the temperature sensor;   determine that the ambient temperature is below a lower temperature threshold; and   operate the heating element to heat the thermostatic drain valve in response to determining that the ambient temperature is below the lower temperature threshold.   
     
     
         17 . The condensate management system of  claim 16 , wherein the lower temperature threshold is between 10° Fahrenheit and 30° Fahrenheit. 
     
     
         18 . The condensate management system of  claim 16 , wherein the higher temperature threshold is 32° Fahrenheit. 
     
     
         19 . The condensate management system of  claim 13 , further comprising a controller in operative communication with the heating element, the controller being configured to:
 activate the heating element;   perform a defrost cycle; and   turn off the heating element a predetermined amount of time after completing the defrost cycle.   
     
     
         20 . The condensate management system of  claim 19 , wherein the predetermined amount of time is between 30 minutes and 120 minutes.