Condensate management system for an air conditioner appliance

Abstract

An air conditioner unit includes a bulkhead defining 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, a wall sleeve defining a mechanical compartment configured for receiving at least a portion of the base pan, the indoor heat exchanger, and the outdoor heat exchanger, and a thermal distributor element mounted within the base pan and defining a top surface and a bottom surface, wherein the top surface at least partially defines a condensate collection reservoir and the bottom surface is positioned within a gap defined between the base pan and the wall sleeve.

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 defining 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;   a wall sleeve defining a mechanical compartment configured for receiving at least a portion of the base pan, the indoor heat exchanger, and the outdoor heat exchanger; and   a thermal distributor element mounted within the base pan and defining a top surface and a bottom surface, wherein the top surface at least partially defines a condensate collection reservoir and the bottom surface is positioned within a gap defined between the base pan and the wall sleeve.   
     
     
         2 . The air conditioner unit of  claim 1 , wherein the thermal distributor element comprises a flat plate. 
     
     
         3 . The air conditioner unit of  claim 1 , wherein the thermal distributor element is constructed from metal or stainless steel. 
     
     
         4 . The air conditioner unit of  claim 1 , wherein the thermal distributor element is overmolded into an aperture defined in the base pan. 
     
     
         5 . The air conditioner unit of  claim 1 , wherein the thermal distributor element is attached to the base pan using an adhesive. 
     
     
         6 . The air conditioner unit of  claim 1 , wherein the base pan defines one or more pan holes for discharging the condensate, and wherein the thermal distributor element extends to the one or more pan holes. 
     
     
         7 . The air conditioner unit of  claim 1 , wherein the thermal distributor element defines a cutout for a drain valve. 
     
     
         8 . The air conditioner unit of  claim 1 , wherein the thermal distributor element forms a trough under the outdoor heat exchanger. 
     
     
         9 . The air conditioner unit of  claim 1 , wherein the base pan is formed from plastic. 
     
     
         10 . 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). 
     
     
         11 . The air conditioner unit of  claim 1 , wherein the wall sleeve is made from stainless steel or painted steel and is mountable within an opening in a building wall. 
     
     
         12 . 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;   a wall sleeve defining a mechanical compartment configured for receiving at least a portion of the base pan, the indoor heat exchanger, and the outdoor heat exchanger; and   a thermal distributor element mounted within the base pan and defining a top surface and a bottom surface, wherein the top surface at least partially defines a condensate collection reservoir and the bottom surface is positioned within a gap defined between the base pan and the wall sleeve.   
     
     
         13 . The condensate management system of  claim 12 , wherein the thermal distributor element comprises a flat plate. 
     
     
         14 . The condensate management system of  claim 12 , wherein the thermal distributor element is constructed from metal or stainless steel. 
     
     
         15 . The condensate management system of  claim 12 , wherein the thermal distributor element is overmolded into an aperture defined in the base pan. 
     
     
         16 . The condensate management system of  claim 12 , wherein the thermal distributor element is attached to the base pan using an adhesive. 
     
     
         17 . The condensate management system of  claim 12 , wherein the base pan defines one or more pan holes for discharging the condensate, and wherein the thermal distributor element extends to the one or more pan holes. 
     
     
         18 . The condensate management system of  claim 12 , wherein the thermal distributor element defines a cutout for a drain valve. 
     
     
         19 . The condensate management system of  claim 12 , wherein the thermal distributor element forms a trough under the outdoor heat exchanger. 
     
     
         20 . The condensate management system of  claim 12 , wherein the base pan is formed from plastic.