Condensate management system for an air conditioner appliance

Abstract

An air conditioner unit includes 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, 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 defrost heater mounted 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 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;   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 defrost heater mounted within a gap defined between the base pan and the wall sleeve.   
     
     
         2 . The air conditioner unit of  claim 1 , wherein the defrost heater is mounted to a bottom of the base pan. 
     
     
         3 . The air conditioner unit of  claim 1 , wherein the defrost heater is mounted to the wall sleeve. 
     
     
         4 . The air conditioner unit of  claim 1 , wherein the defrost heater is mounted proximate a pan hole. 
     
     
         5 . The air conditioner unit of  claim 4 , wherein the defrost heater surrounds the pan hole. 
     
     
         6 . The air conditioner unit of  claim 1 , wherein the defrost heater extends to a discharge port defined on the wall sleeve. 
     
     
         7 . The air conditioner unit of  claim 1 , wherein the defrost heater defines cutouts or channels for guiding the condensate out of the wall sleeve. 
     
     
         8 . The air conditioner unit of  claim 1 , wherein the defrost heater is a resistive heater. 
     
     
         9 . The air conditioner unit of  claim 1 , further comprising an ambient temperature sensor and a controller in operative communication with the ambient temperature sensor, the controller being configured to:
 determine that a defrost cycle is requested;   obtain an ambient temperature using the ambient temperature sensor;   determine that the ambient temperature is below a predetermined temperature threshold; and   activate the defrost heater and perform the defrost cycle.   
     
     
         10 . The air conditioner unit of  claim 9 , wherein the controller is further configured to:
 determine that the ambient temperature is at or above the predetermined temperature threshold; and   deactivate the defrost heater.   
     
     
         11 . The air conditioner unit of  claim 9 , wherein the predetermined temperature threshold is 32° F. 
     
     
         12 . The air conditioner unit of  claim 9 , wherein the controller is further configured to:
 determine the defrost cycle is not being performed; and   stop operating the defrost heater.   
     
     
         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;   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 defrost heater mounted within a gap defined between the base pan and the wall sleeve.   
     
     
         14 . The condensate management system of  claim 13 , wherein the defrost heater is mounted to a bottom of the base pan or to the wall sleeve. 
     
     
         15 . The condensate management system of  claim 13 , wherein the defrost heater is mounted proximate a pan hole. 
     
     
         16 . The condensate management system of  claim 15 , wherein the defrost heater surrounds the pan hole. 
     
     
         17 . The condensate management system of  claim 13 , wherein the defrost heater extends to a discharge port defined on the wall sleeve. 
     
     
         18 . The condensate management system of  claim 13 , wherein the defrost heater defines cutouts or channels for guiding the condensate out of the wall sleeve. 
     
     
         19 . The condensate management system of  claim 13 , further comprising an ambient temperature sensor and a controller in operative communication with the ambient temperature sensor, the controller being configured to:
 determine that a defrost cycle is requested;   obtain an ambient temperature using the ambient temperature sensor;   determine that the ambient temperature is below a predetermined temperature threshold; and   activate the defrost heater and perform the defrost cycle.   
     
     
         20 . The condensate management system of  claim 19 , wherein the controller is further configured to:
 determine that the ambient temperature is at or above the predetermined temperature threshold; and   deactivate the defrost heater.