U.S. patent application number 11/490538 was filed with the patent office on 2007-02-01 for microclimate creator system and method for cooling units.
Invention is credited to Mingsheng Liu.
Application Number | 20070022774 11/490538 |
Document ID | / |
Family ID | 37692808 |
Filed Date | 2007-02-01 |
United States Patent
Application |
20070022774 |
Kind Code |
A1 |
Liu; Mingsheng |
February 1, 2007 |
Microclimate creator system and method for cooling units
Abstract
A system and method for use with a cooling unit including a
condenser. In one embodiment, the system comprises a fog creator
and a residue collection component. The fog creator includes
water-emitting components and a control device. The water-emitting
components are configured to be positioned proximate to the cooling
unit and to emit water that produces a fog zone external to the
cooling unit. The control device is configured to control a supply
of water to the water-emitting components. The residue collection
component is configured to be positioned proximate to coils of the
condenser, to protect the condenser coils from residue buildup, and
to allow outside air cooled by the fog zone to flow to the
condenser coils.
Inventors: |
Liu; Mingsheng; (Omaha,
NE) |
Correspondence
Address: |
MICHAEL BEST & FRIEDRICH, LLP
100 E WISCONSIN AVENUE
MILWAUKEE
WI
53202
US
|
Family ID: |
37692808 |
Appl. No.: |
11/490538 |
Filed: |
July 20, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60701684 |
Jul 22, 2005 |
|
|
|
Current U.S.
Class: |
62/305 ;
62/121 |
Current CPC
Class: |
F24F 1/50 20130101; F28C
1/00 20130101; F24F 1/42 20130101; F25B 2339/041 20130101; Y02B
30/70 20130101; F28D 5/00 20130101; F28F 27/003 20130101; F24F 1/48
20130101 |
Class at
Publication: |
062/305 ;
062/121 |
International
Class: |
F28D 5/00 20060101
F28D005/00; F28C 1/00 20060101 F28C001/00 |
Claims
1. A system for use with a cooling unit including a condenser, the
system comprising: a fog creator including a plurality of
water-emitting components configured to be positioned proximate to
the cooling unit and to emit water, the emitted water producing a
fog zone external to the cooling unit, and a control device
configured to control a supply of water to the water-emitting
components; and a residue collection component configured to be
positioned proximate to coils of the condenser, to protect the
condenser coils from residue buildup, and to allow outside air
cooled by the fog zone to flow to the condenser coils.
2. The system of claim 1, wherein the cooling unit comprises an air
conditioner.
3. The system of claim 1, wherein the water-emitting components
comprise nozzles.
4. The system of claim 1, wherein the control device comprises a
valve having an operational state that is dependent on an
operational state of a compressor of the cooling unit.
5. The system of claim 1, wherein the residue collection component
comprises a plurality of louvers.
6. The system of claim 5, further comprising a plurality of guide
rings configured to receive the louvers.
7. The system of claim 1, wherein residue includes at least one of
mineral residue, water mist, and dust.
8. The system of claim 1, further comprising the cooling unit.
9. The system of claim 1, further comprising a pump configured to
increase pressure of water from the water supply.
10. The system of claim 1, wherein the fog creator further
comprises at least one conduit configured to link the
water-emitting components with the control device.
11. A method for use with a cooling unit including a condenser, the
method comprising: supplying water to water-emitting components
positioned proximate to the cooling unit; producing, by the
water-emitting components, a fog zone external to the cooling unit;
preventing, by a residue collection component, residue from
collecting on coils of the condenser; and receiving, by the
condenser coils, outside air cooled by the fog zone.
12. The method of claim 11, wherein water is selectively supplied
to the water-emitting components.
13. The method of claim 12, wherein water is supplied to the
water-emitting components when a compressor of the cooling unit is
enabled.
14. The method of claim 12, wherein water is supplied to the
water-emitting components based at least in part on sensed relative
humidity of outside air.
15. The method of claim 11, wherein the cooling unit comprises a
commercial rooftop unit.
16. An installation method for a cooling unit including a
condenser, the method comprising: positioning a plurality of
water-emitting components proximate to the cooling unit, the
water-emitting components configured to emit water, the emitted
water producing a fog zone external to the cooling unit; coupling
the water-emitting components to a control device, the control
device configured to control a supply of water to the
water-emitting components; coupling the control device to the water
supply; and positioning a residue collection component proximate to
coils of the condenser, the residue collection component configured
to protect the condenser coils from residue buildup, and to allow
outside air cooled by the fog zone to flow to the condenser
coils.
17. The method of claim 16, wherein the residue collection
component comprises a plurality of louvers, the method further
comprising threading the louvers onto a plurality of guide
rings.
18. The method of claim 16, wherein the cooling unit is an existing
cooling unit being retrofitted by the installation method.
Description
RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent
Application Ser. No. 60/701,684, filed Jul. 22, 2005, the entire
contents of which are incorporated herein by reference.
FIELD
[0002] Embodiments of the invention relate generally to cooling
units. More specifically, embodiments of the invention relate to
systems and methods to improve performance of air-cooled condensing
systems.
BACKGROUND
[0003] Various cooling units, such as residential air conditioning
(A/C) units, commercial rooftop A/C units, and air-cooled chillers,
employ fans that blow air over condenser coils in order to
dissipate heat (to the outside air) and cold (to the area(s) being
cooled).
SUMMARY
[0004] The following summary sets forth certain exemplary
embodiments of the invention. It does not set forth all such
embodiments and is not limiting of embodiments of the
invention.
[0005] Embodiments of the invention relate to systems and methods
to improve performance of air-cooled condensing systems.
[0006] In one embodiment, a system for use with a cooling unit that
includes a condenser comprises a fog creator and a residue
collection component. The fog creator includes water-emitting
components and a control device. The water-emitting components are
configured to be positioned proximate to the cooling unit and to
emit water that produces a fog zone external to the cooling unit.
The control device is configured to control a supply of water to
the water-emitting components. The residue collection component is
configured to be positioned proximate to coils of the condenser, to
protect the condenser coils from residue buildup, and to allow
outside air cooled by the fog zone to flow to the condenser
coils.
[0007] In another embodiment, a method for use with a cooling unit
that includes a condenser comprises supplying water to
water-emitting components positioned proximate to the cooling unit;
producing, by the water-emitting components, a fog zone external to
the cooling unit; preventing, by a residue collection component,
residue from collecting on coils of the condenser; and receiving,
by the condenser coils, outside air cooled by the fog zone.
[0008] In another embodiment, an installation method for a cooling
unit that includes a condenser comprises positioning water-emitting
components proximate to the cooling unit. The water-emitting
components are configured to emit water to produce a fog zone
external to the cooling unit. The installation method further
comprises coupling the water-emitting components to a control
device that is configured to control a supply of water to the
water-emitting components; coupling the control device to the water
supply; and positioning a residue collection component proximate to
coils of the condenser. The residue collection component is
configured to protect the condenser coils from residue buildup, and
to allow outside air cooled by the fog zone to flow to the
condenser coils.
[0009] Various embodiments herein can enable an air-cooled
condensing system to perform at a level consistent with the
performance level of water-cooled systems, while avoiding the need
for a costly cooling tower and eliminating associated maintenance
costs. Moreover, various embodiments herein can be incorporated in
existing or new systems. Because of reduced energy costs that can
be realized by various embodiments herein, incremental
implementation costs can be recouped over time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 shows a system according to an embodiment of the
invention.
[0011] FIG. 2 shows a perspective view of a microclimate creator
according to an embodiment of the invention.
[0012] FIG. 3 shows a cross-sectional view of the microclimate
creator of FIG. 2.
[0013] FIGS. 4A, 4B, and 4C show various views of an exemplary
louver strip according to an embodiment of the invention.
[0014] FIG. 5 shows a method according to an embodiment of the
invention.
[0015] FIG. 6 shows a method according to an embodiment of the
invention.
DETAILED DESCRIPTION
[0016] Before any embodiments of the invention are explained in
detail, it is to be understood that the invention is not limited in
its application to the details of construction and the arrangement
of components set forth in the following description or illustrated
in the following drawings. The invention is capable of other
embodiments and of being practiced or of being carried out in
various ways. Also, it is to be understood that the phraseology and
terminology used herein is for the purpose of description and
should not be regarded as limiting. The use of "including,"
"comprising," or "having" and variations thereof herein is meant to
encompass the items listed thereafter and equivalents thereof as
well as additional items. Unless specified or limited otherwise,
the terms "mounted," "connected," "supported," and "coupled" and
variations thereof are used broadly and encompass both direct and
indirect mountings, connections, supports, and couplings. Further,
"connected" and "coupled" are not restricted to physical or
mechanical connections or couplings.
[0017] Embodiments of the invention relate to systems and methods
to improve performance of air-cooled condensing systems. In various
embodiments, a fog zone is artificially created outside a cooling
unit. When outside air being drawn into the condenser of the
cooling unit flows through the fog zone, its temperature is
reduced, which increases the cooling capacity and energy efficiency
of the cooling unit. Further, the incoming air stream is cleaned by
the fog zone, and peak electricity demand is reduced. In various
embodiments, structures are optionally employed to prevent minerals
and other substances from depositing on condenser coils of a
cooling unit.
[0018] Embodiments herein are applicable to a host of cooling unit
types, such as, for example, residential air conditioning (A/C)
units, commercial rooftop A/C units, and air-cooled chillers.
Moreover, embodiments can be applied to retrofit existing cooling
units or can be incorporated as original equipment in new cooling
units.
[0019] FIG. 1 shows a system 100 according to an embodiment of the
invention. The system 100 includes a fog creator 110, a residue
collection component 120, and a cooling unit 130. In some
embodiments, all or a portion of the fog creator 110 and/or the
residue collection component 120 are part of the cooling unit 130.
In other embodiments, the fog creator 110 and the residue
collection component 120 are separate structures and/or devices
employed in conjunction with the cooling unit 130 (e.g., to
retrofit a cooling unit).
[0020] The fog creator 110 includes water-emitting components 140
and a control device 150. The water-emitting components 140 may be
separate devices interconnected by conduits (e.g., discrete nozzles
linked together by conduits) or unitary devices (e.g., a device
that has multiple nozzles or heads therein). The water-emitting
components 140 are typically positioned near the cooling unit 130
so that the water emitted thereby produces a fog zone external to
the cooling unit 130, thereby cooling the air stream entering the
condenser (not shown) of the cooling unit 130 and cleaning the air
stream.
[0021] The control device 150 controls a supply of water to the
water-emitting components 140. As such, the water-emitting
components 140 can selectively emit water, such as when a
compressor (not shown) of the cooling unit 130 is enabled. The
control device 150 and the water-emitting components 140 can be
implemented discretely or as a unitary device.
[0022] The residue collection component 120 is typically positioned
near the condenser coils in order to protect the condenser coils
from buildup of residue, such as mineral residue, water mist, and
dust. Additionally, the residue collection component 120 allows
outside air cooled by the fog zone to flow to the condenser
coils.
[0023] FIG. 2 shows a perspective view of a microclimate creator
200 according to an embodiment of the invention. The microclimate
creator 200 is one exemplary implementation of the fog creator 110
and residue collection component 120 of FIG. 1. The microclimate
creator 200 includes nozzles 210, one or more conduits (e.g.,
pipes) 220, a control valve 230, and louvers 240. The microclimate
creator 200 is positioned outside a cooling unit 205. In
particular, the louvers 240 substantially surround the condenser
coils of the cooling unit 205, and the nozzles 210 are positioned
outside the louvers 240. The generally cube-like shape of the
cooling unit 205 and surrounding louvers 240 in FIG. 2 is merely
exemplary. Other configurations are within the scope of embodiments
of the invention. The configuration of the illustrated louvers 240
is more clearly shown in FIG. 3 (discussed below). Suitable
supporting structures (not shown) can be provided for the nozzles
210, conduits 220, control valve 230, and louvers 240. For
instance, one or more frames can be provided that surround a
cooling unit and support portions of a microclimate creator.
Alternatively or additionally, the cooling unit can directly or
indirectly (e.g., via retrofitted structures attached to the
cooling unit) support portions of a microclimate creator.
[0024] The nozzles 210 are linked to the control valve 230 by one
or more conduits 220. In some embodiments, multiple spaced nozzles
and conduits are integrated into a single structure. The control
valve 230 is in turn linked to a water source 250, such as a city
water supply, by one or more conduits 220. As shown, the nozzles
210 are arranged in a single nozzle ring 215. In some
implementations, multiple nozzle rings 215 are employed depending
on the height of the condenser of the cooling unit 205. For
example, nozzle rings 215 can be positioned at various positions
along the vertical axis of the cooling unit 205 so as to ensure
that outside air around the cooling unit 205 flows through a fog
zone. In various embodiments, the nozzles 210 are slightly tilted
away from the condenser to achieve effective cooling.
[0025] In some embodiments, the water pressure of the water source
250 is approximately 15 psig (pounds per square inch gauge) or
greater. A pump (not shown) optionally may be coupled to the water
source 250 to increase the water pressure to 15 psig or another
desired pressure.
[0026] The control valve 230 can be any suitable fluid control
device, such as a solenoid valve or a motorized ball valve. In an
exemplary implementation, the control valve 230 is a solenoid valve
having open and closed states. In the open state, the control valve
230 allows the flow of water from the water source 250 through the
conduits 220 to the nozzles 210, thereby causing the nozzles 210 to
emit water so as to produce a fog or mist zone around the cooling
unit 205. In the closed state, the control valve 230 impedes the
flow of water from the water source 250 through the conduits 220 to
the nozzles 210; as such, the nozzles 210 do not emit water, and no
fog or mist zone is produced around the cooling unit 205.
[0027] In some embodiments, the control valve 230 is opened or
closed based on operation of one or more components of the cooling
unit 205 and/or based on environmental and/or other conditions. For
instance, in an exemplary implementation, the control valve 230 is
electrically connected to a relay of the compressor (not shown) of
the cooling unit 205. When the compressor turns on, the control
valve 230 opens after a predetermined time period, such as 30
seconds. When the compressor turns off, the control valve 230 is
closed after a predetermined time period, such as substantially
instantaneously. In another exemplary implementation, the control
valve 230 is electrically connected to a sensor, such as a sensor
that measures the relative humidity of outside air. If the measured
relative humidity is higher than 75% (indicating that outside air
is moist and that fog will not decrease the air temperature
significantly), the control valve 230 closes, thereby impeding the
flow of water to the nozzles 210 and preventing a fog zone from
being produced. In other embodiments, a control valve and a nozzle
are integrated together, and/or a microcontroller and/or other
suitable circuitry are interfaced with a control valve and/or a
nozzle.
[0028] The louvers 240 prevent residue, such as mineral residue,
water mist, dust, and other substances, from reaching the coils of
the condenser. In an exemplary implementation, the louvers 240
encircle the condenser coils and are arranged upwardly, thereby
blocking residue and allowing outside air cooled by the fog zone to
flow to the condenser coils.
[0029] FIG. 3 shows a cross-sectional view of the microclimate
creator 200 of FIG. 2. Structures of the cooling unit 205 are also
shown, including condenser coils 310, a condenser fan 260, and a
compressor 320. Outside air 330 flows through the fog zone 340,
into the louver zone 350, to the condenser coils 310, and into the
cooling unit 205.
[0030] During operation of the cooling unit 205, the condenser fan
260 is typically turned on before or at the same time as the
compressor 320 is turned on. The condenser fan 260 draws outside
air 330 through the fog zone 340, the louver zone 350, and the
condenser coils 310, and rejects air to the outside of the cooling
unit 205. When the outside air 330 flows through the fog zone 340,
heat and mass transfer occurs between the dry, hot outside air 330
and the water mist. Heat and mass transfer continues in the louver
zone 350. The dry, hot outside air 330 is cooled down by the latent
heat of the water mist. Ideally, the outside air 330 can be cooled
down to the wet bulb temperature of the outside air 330. Since the
wet bulb temperature is often 15.degree. F. to 30.degree. F. lower
than the dry bulb temperature, the condenser can receive air at a
temperature as low as 60.degree. F. to 80.degree. F., which
significantly increases the cooling capacity of the cooling unit
205. Additionally, due to moderate condensing temperature, the
cooling unit 205 has measurably higher energy performance.
[0031] In some embodiments, a fog creator is designed in part based
on considerations of water flow. In particular, the total water
flow rate, GPH, needed to produce a fog zone may be determined
using the following formula: GPH=0.5CFM(W.sub.wet-W.sub.o,a)
[0032] GPH is the total water flow rate of the fog zone expressed
in gallons per hour. CFM is the airflow rate of the cooling unit
expressed in cubic feet per minute. W.sub.wet is the saturated
humidity ratio at the wet bulb temperature. W.sub.o,a is the
humidity ratio of outside air. The W.sub.wet and W.sub.o,a values
correspond to temperature and relative humidity values that would
be typical of the outside air surrounding a cooling unit during
times of operation.
[0033] The number of nozzles, N, needed to produce the fog zone is
determined based on the total water flow rate, GPH, and the water
flow rate per nozzle, gph. The formula is as follows: N=GPH/gph
[0034] FIGS. 4A, 4B, and 4C show front, top, and side views,
respectively, of an exemplary louver strip 400 according to an
embodiment of the invention. In the embodiment shown, the louver
strip 400 is made of plastic, metal, or other suitable materials
that have elastic properties. It is to be appreciated that other
types of structures may be utilized to perform the residue
collection function of louvers, such as filters or panels of
varying shapes and dimensions. Similarly, the actual shapes and
dimensions of louvers can be tailored depending on the
configuration of a cooling unit. Accordingly, the louvers
specifically described herein are merely exemplary and not limiting
of embodiments of the invention.
[0035] The strip width of the illustrated louver strip 400 is
between approximately 3 and 5 inches. During manufacturing, a
louver strip 420 may be folded in an accordion-like manner, as
shown in FIGS. 4A and 4B. Holes may be pre-made on both ends of
each louver blade 420, as shown in FIG. 4C.
[0036] In a factory or at the location of a cooling unit, guide
rings (not shown) may be tailored to the size and shape of the
condenser coils. Folded louver strips 400 can then be threaded onto
the guide rings. The folded strips 400 can be stretched out to
minimize the use of louver materials and to enable the louvers to
conform to curves and/or corners without the need for cutting off
portions of louver strips.
[0037] FIG. 5 shows a method 500 according to an embodiment of the
invention. The method 500 can be applied to improve performance of
an existing or new cooling unit. In task T510, water is supplied to
water-emitting components positioned near a cooling unit. In task
T520, the water-emitting components produce a fog zone external to
the cooling unit. In task T530, a residue collection component
prevents residue from collecting on coils of a condenser of the
cooling unit. In task T540, the condenser coils receive outside air
cooled by the fog zone.
[0038] FIG. 6 shows a method 600 according to an embodiment of the
invention. The method 600 can be applied to retrofit an existing
cooling unit in accordance with embodiments of the invention, or to
incorporate embodiments in a new cooling unit. For instance,
certain tasks below may be performed at a factory during
manufacture of a new cooling unit. In task T610, water-emitting
components are positioned near a cooling unit. In task T620, the
water-emitting components are coupled to a control device that
controls a supply of water to the water-emitting components such
that the water-emitting components can produce a fog zone. In task
T630, the control device is coupled to the water supply. In task
T640, a residue collection component is positioned near the coils
of a condenser of the cooling unit in order to protect the
condenser coils from residue buildup, and to allow outside air
cooled by the fog zone to flow to the condenser coils.
[0039] Various features and advantages of the invention are set
forth in the following claims.
* * * * *