Indoor AC Refrigerant Sensor Cover to Block Condensate Ingress
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Solution Overview
Problem
Existing air-conditioning apparatuses face issues with sensors detecting refrigerant leakage, as they can become wet due to condensate water, leading to potential failure, and gas sensors can malfunction when water enters through air holes.
Innovation Solution
An air-conditioning apparatus design featuring a refrigerant detection unit with a sensor covered by a sensor cover that includes a roof portion and side surface portions with eaves, and opening ports to introduce air, while being mounted on a back surface to prevent water ingress, and optionally using a fine particle adsorption filter to prevent erroneous gas detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor is arranged in the vicinity of the drain pan to detect refrigerant leakage, then the detection capability is improved, but the sensor may be wetted by condensate water dripping from the drain pan
Solution Approach 1:
The sensor assembly is divided into separate functional components: the sensor unit, the cover body with water diversion structure, and the mounting structure. This segmentation allows the cover body to independently perform water diversion while the sensor focuses on detection, resolving the contradiction between detection capability and reliability.
Solution Approach 2:
The cover body acts as an intermediary element between the drain pan and the sensor. It provides a protective interface that diverts condensate water away from the sensor while allowing the sensor to remain positioned for effective refrigerant leakage detection. The cover body mediates the conflict between proximity to the drain pan and protection from water.
2Measurement precision
If air holes are formed in the frame member to introduce air to the gas detection device, then the detection sensitivity is improved, but water can enter through the air holes and cause sensor failure
Solution Approach 1:
The eaves portion is provided at specific locations (front and side surfaces) of the cover body where water diversion is most critical. This localized structural feature creates a quality difference in the cover body design, providing water protection at key entry points while maintaining air intake capability through the front surface opening.
Solution Approach 2:
The eaves portion extends in the depth direction of the cover body, creating a three-dimensional water diversion structure. This dimensional extension allows the eaves to effectively block water from entering through the side and front surfaces while maintaining air flow paths, resolving the contradiction between air intake and water protection.
3Reliability
If the sensor is covered to protect it from water, then the reliability is improved, but air intake for detection may be restricted
Solution Approach 1:
The cover body performs multiple functions simultaneously: it protects the sensor from water, introduces air to the sensor for detection, and diverts condensate water away from the sensor. This multi-functionality reduces the need for separate protective structures, maintaining simplicity while achieving comprehensive protection and detection capability.
Solution Approach 2:
The cover body is designed as a thin-walled structure with integrated water diversion features (eaves portions) rather than a bulky enclosure. This flexible shell design provides effective water protection while minimizing interference with air flow and maintaining overall structural simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design effectively prevents sensor wetting and enhances detection accuracy by ensuring air can enter the sensor cover while keeping water out, and reduces erroneous gas detection through the use of fine particle filters.
Implementation Method 1
the roof portion has an eaves portion projecting outward with respect to the side surface portion
Implementation Method 2
the eaves portion projecting outward... configured to prevent water from entering an inside of the sensor cover
Implementation Method 3
a sensor configured to detect leakage of the refrigerant
Implementation Method 4
the side surface portion has at least one first opening port configured to introduce air to an inside of the sensor cover
Data Source
AI summary
An indoor unit of an air-conditioning apparatus includes: a casing; a drain pan, which is provided inside the casing, and is configured to receive condensate water generated in the load-side heat exchanger; and a refrigerant detection unit provided below the drain pan inside the casing. The refrigerant detection unit includes: a sensor configured to detect leakage of the refrigerant; and a sensor cover configured to cover the sensor from a front surface side of the sensor. The sensor cover includes: a roof portion arranged above the sensor; and a side surface portion arranged on the front surface side or a side surface side of the sensor below the roof portion. The roof portion has an eaves portion projecting outward with respect to the side surface portion, and the side surface portion has at least one first opening port configured to introduce air to an inside of the sensor cover therethrough.