Air conditioner containing drain pan and refrigerant sensor

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Solution Overview

Problem

Air conditioners using refrigerants like A2L face issues with leaks that can be hazardous, inefficient, and costly, necessitating a compact refrigerant sensor that minimizes space usage while effectively detecting leaks.

Innovation Solution

A refrigerant sensor is integrated into the air conditioner's drain pan, either in a recess or between the drain pan and housing, protected by a casing, to minimize space and enhance detection efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a refrigerant sensor is added to detect leaks, then safety and reliability improve, but device complexity and space requirements increase

Engineering Contradiction:

Improveleak detection capabilityVSAvoidsensor integration complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The refrigerant sensor is merged with the drain pan structure by integrating it into a recess of the drain pan. This combination allows the sensor to be positioned close to the heat exchanger for effective leak detection while utilizing existing structural space, thereby improving reliability without proportionally increasing device complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The drain pan structure serves multiple functions: it collects condensation water and simultaneously houses the refrigerant sensor through its recess structure. This multi-functionality reduces the need for separate sensor mounting structures, addressing the contradiction between improved leak detection and reduced device complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a refrigerant sensor is added to detect leaks, then safety and reliability improve, but the space occupied by the air conditioner increases

Engineering Contradiction:

Improveleak detection capabilityVSAvoidair conditioner space occupation

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The refrigerant sensor is nested within the recess of the drain pan structure. This nesting approach allows the sensor to be accommodated within the existing footprint of the air conditioner without requiring additional external space, thereby improving reliability while minimizing volume increase

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

Instead of adding the sensor in a horizontal direction that would increase the width of the air conditioner, the sensor is positioned vertically within the recess of the drain pan. This dimensional repositioning allows effective leak detection close to the heat exchanger while maintaining the original horizontal footprint of the device

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Measurement precision

If the refrigerant sensor is positioned close to the heat exchanger, then detection precision improves, but the risk of water damage to the sensor increases

Engineering Contradiction:

Improverefrigerant leak detection precisionVSAvoidwater damage risk to sensor

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The recess structure provides localized protection to the sensor by creating a physical barrier that shields it from water while maintaining close proximity to the heat exchanger for accurate leak detection. This local structural modification addresses the contradiction by providing differential protection: the sensor remains exposed to refrigerant vapors for detection while being protected from liquid water

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The recess structure acts as an intermediary element between the sensor and the water drainage path. It allows the sensor to be positioned close to the heat exchanger for precise detection while the recess walls serve as a protective barrier against water damage, mediating between the conflicting requirements of detection precision and protection from harmful factors

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution allows for effective detection of refrigerant leaks near the drain pan, reducing health and fire risks while maintaining air conditioner efficiency and minimizing space requirements.

Implementation Method 1

a refrigerant sensor arranged proximate to a first outer surface of a first drain pan wall selected from the plurality of drain pan walls, the refrigerant sensor being configured to detect refrigerant in air proximate to the drain pan

Methodology Applied

Scientific EffectDiffusion: Diffusion

Data Source

PatentUS20250305716A1Air conditioner containing drain pan and refrigerant sensor

Publication Date: 2025.10.02 MITSUBISHI ELECTRIC US

AI summary

An air conditioner is provided, comprising: a drain pan including plurality of drain pan walls forming an outer circumference of the drain pan, and a drain pan bottom, connected to each of the plurality of drain pan walls such that the plurality of drain pan walls and the drain pan bottom form a basin capable of collecting liquid; and a refrigerant sensor arranged proximate to a first outer surface of a first drain pan wall selected from the plurality of drain pan walls, the refrigerant sensor being configured to detect refrigerant in air proximate to the drain pan. The first drain pan wall includes a first recess on the first outer surface, and the refrigerant sensor is located in the first recess.