U.S. patent application number 12/821958 was filed with the patent office on 2010-12-30 for dehumidifier for use in water damage restoration.
This patent application is currently assigned to Karcher North America, Inc.. Invention is credited to Nicholas Brian O'Kane, Doug Shipe, Stephen Stamm.
Application Number | 20100326103 12/821958 |
Document ID | / |
Family ID | 43379259 |
Filed Date | 2010-12-30 |
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United States Patent
Application |
20100326103 |
Kind Code |
A1 |
Stamm; Stephen ; et
al. |
December 30, 2010 |
Dehumidifier for Use in Water Damage Restoration
Abstract
A transportable dehumidifier system is provided that employs a
thermal expansion valve to control the flow of refrigerant
therethrough.
Inventors: |
Stamm; Stephen; (Wheat
Ridge, CO) ; Shipe; Doug; (Highlands Ranch, CO)
; O'Kane; Nicholas Brian; (Highlands Ranch, CO) |
Correspondence
Address: |
SHERIDAN ROSS PC
1560 BROADWAY, SUITE 1200
DENVER
CO
80202
US
|
Assignee: |
Karcher North America, Inc.
Englewood
CO
|
Family ID: |
43379259 |
Appl. No.: |
12/821958 |
Filed: |
June 23, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61219888 |
Jun 24, 2009 |
|
|
|
Current U.S.
Class: |
62/176.6 ;
62/222; 62/498; 62/513 |
Current CPC
Class: |
F25B 2600/2513 20130101;
F24F 2221/125 20130101; F24F 3/1405 20130101 |
Class at
Publication: |
62/176.6 ;
62/498; 62/222; 62/513 |
International
Class: |
F25B 49/02 20060101
F25B049/02; F25B 1/00 20060101 F25B001/00; F25B 41/04 20060101
F25B041/04; F25B 41/00 20060101 F25B041/00 |
Claims
1. A portable dehumidifier, comprising: a housing having an inlet
opening for receiving air of a first humidity and an exit opening
for expelling air of a second humidity; an evaporator positioned
adjacent to said inlet opening, said evaporator having an inlet
tube and an outlet tube; a compressor interconnected to the
evaporator via a outlet tube of the evaporator, the compressor
having an exit tube; a condenser interconnected to the exit tube of
the compressor, the condenser having an exit tube that is
interconnected to a thermal expansion valve that is also associated
with the inlet tube of the evaporator; a sensor associated with the
exit tube of the evaporator; and wherein the sensor communicates
with the thermal expansion valve to control flow of refrigerant
flowing through the evaporator, compressor, and tubes.
2. The portable dehumidifier of claim 1, wherein said evaporator is
a heat exchanger that employs fins and tubes or micro channels.
3. The portable dehumidifier of claim 1, wherein said condenser is
a heat exchanger that employs fins and tubes or micro channels.
4. The portable dehumidifier of claim 1, further comprising a pump
that is associated with a reservoir that receives moisture from
said evaporator.
5. The portable dehumidifier of claim 1, further comprising a means
for chilling air positioned between the inlet opening and the
evaporator.
6. The portable dehumidifier of claim 1, further comprising an
inlet temperature sensor associated with the inlet opening and an
outlet temperature sensor associated with the exit opening.
7. The portable dehumidifier of claim 1, wherein a portion of the
housing defines an air path.
8. The portable dehumidifier of claim 1, wherein at least a portion
of the housing is removable.
9. A dehumidifier, comprising: an evaporator; a compressor
associated with the evaporator; a condenser associated with the
compressor; a valve associated with the condenser and the
evaporator; a sensor that is associated with the valve; and wherein
the sensor communicates with the valve to control flow of
refrigerant through the portable dehumidifying system.
10. The dehumidifier of claim 9, wherein said evaporator is a heat
exchanger that employs fins and tubes or micro channels.
11. The dehumidifier of claim 9, wherein said condenser is a heat
exchanger that employs fins and tubes or micro channels.
12. The dehumidifier of claim 9, further comprising a pump that is
associated with a reservoir that receives moisture from said
evaporator.
13. The dehumidifier of claim 9, further comprising a means for
chilling air positioned between the inlet opening and the
evaporator.
14. The portable dehumidifier of claim 9, further comprising an
inlet temperature sensor associated with the inlet opening and an
outlet temperature sensor associated with the exit opening.
15. The dehumidifier of claim 9, wherein the valve is a thermal
expansion valve;
16. The portable dehumidifier of claim 9, further including a
housing positioned about the evaporator and the condenser that
defines an air path.
17. The portable dehumidifier of claim 16, wherein at least a
portion of the housing is removable.
18. A dehumidifier including a compressor for delivering hot
compressed refrigerant, a condenser that receives refrigerant from
said compressor and condenses same, an expansion device that
receives refrigerant from said condenser and expands same, an
evaporator that receives refrigerant from the expansion device and
evaporating same and delivers the refrigerant to the compressor,
the refrigerant being circulated from said compressor to said
condenser to said expansion device to said evaporator and back to
said compressor in a refrigeration cycle, the improvement
comprising: a sensor associated with the evaporator that
communicates with the expansion device to control the flow of
refrigerant through the dehumidifier.
19. The dehumidifier of claim 18 wherein the system is devoid of a
capillary tube.
20. The dehumidifier of claim 18, wherein said evaporator is a heat
exchanger that employs fins and tubes or micro channels.
21. The dehumidifier of claim 18, wherein said condenser is a heat
exchanger that employs fins and tubes or micro channels.
22. The dehumidifier of claim 18 wherein the evaporator, condenser
compressor, expansion device and associated tubes are enclosed with
a housing having an airflow path therethrough.
23. The dehumidifier of claim 18, further comprising an inlet
temperature sensor associated with an inlet opening of the housing
and an outlet temperature sensor associated with an exit opening of
the housing.
24. The dehumidifier of claim 18, further comprising an air-to-air
heat exchanger associated with an inlet of said dehumidifier that
cools air prior to the same entering said evaporator.
25. A portable dehumidifier having a controlled flow of refrigerant
through a system employing a refrigeration cycle that employs an
evaporator, a compressor interconnected to the evaporator via a
first tube, a condenser interconnected to a valve via a second tube
and to the compressor via a third tube, a forth tube interconnects
the valve to the evaporator and a sensor that is associated with
the valve and associated with the fourth tube, comprising: sensing
information related to at least one of temperature and humidity;
and controlling with the valve the flow of refrigerant through the
first, second, third and fourth tubes and the compressor, condenser
and evaporator.
26. A portable dehumidifier for removing water from air,
comprising: a housing having an inlet opening for receiving air of
a first humidity and an exit opening for expelling air of a second
humidity; an evaporator positioned adjacent to said inlet opening,
said evaporator having an inlet tube and an outlet tube; a
compressor interconnected to the evaporator via a outlet tube of
the evaporator, the compressor having an exit tube; a condenser
interconnected to the exit tube of the compressor, the condenser
having an exit tube that is interconnected to a thermal expansion
valve that is also associated with the inlet tube of the
evaporator; a pump that is associated with a reservoir; and wherein
the reservoir includes a sensor that initiates the pump when a
fluid introduced into the reservoir reaches a predetermined level
and wherein the pump operates after the evaporator ceases
dehumidifying air.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The following application claims the benefit of U.S.
Provisional Patent Application Ser. No. 61/219,888, filed Jun. 24,
2009, the entire disclosure of which is incorporated by reference
herein.
[0002] The following patent application is also related to U.S.
Pat. No. 7,281,389, entitled "Enhanced Performance Dehumidifier,"
U.S. Patent Application Publication No. 2008/0028776, entitled
"Enhanced Performance Dehumidifier," U.S. Pat. No. 7,194,870,
entitled "High Performance Dehumidifier," U.S. Pat. No. 6,370,902,
entitled "Apparatus for Dehumidifying Air," and U.S. Pat. No.
7,246,503 entitled "Enhanced Drying Dehumidifier," the entire
disclosures of which are incorporated by reference herein. This
application also directs the attention of one skilled in the art to
the Micro Channel Heat Exchangers made by Danfoss, which are
described at www.danfoss.com.
FIELD OF THE INVENTION
[0003] Embodiments of the present invention are generally related
to dehumidifiers, and more particularly to dehumidifiers with
improved performance and efficiency. More specifically, one
embodiment of the present invention is a transportable
dehumidifying system that is placed in areas that have been damaged
by water and facilitate drying of the area by removal of humidity
from surrounding air. It is anticipated that such devices can be
combined with other damage remediation components to form an
integrated system useful in efficiently and effectively remediating
a water damaged structure.
BACKGROUND OF THE INVENTION
[0004] Dehumidifiers are generally comprised of a compressor, an
evaporator and a condenser, linked by a series of tubes to form a
continuous refrigerant cycle. The compressor delivers hot
compressed refrigerant gas to the condenser that condenses the hot
compressed refrigerant gas into hot refrigerant liquid. An
expansion device receives the hot refrigerant liquid from the
condenser and expands same to reduce the temperature and pressure
of the refrigerant. The evaporator receives the cool liquid
refrigerant from the expansion device and evaporates same to yield
cold gas refrigerant that is returned to the compressor to complete
the refrigeration cycle. Air is dehumidified by directing
moisture-laden air across the evaporator, which cools the air below
the dew point thereof so that water vapor trapped in the air, i.e.
humidity, condenses into a liquid. The dehumidified air is then
directed across the condenser to warm the air which may be
redirected to a water damaged area to facilitate drying of the
same. For a concise explanation of dehumidifiers and portable
dehumidifiers, please see above-identified U.S. Pat. No.
7,281,398.
[0005] One drawback of existing dehumidifiers is that a capillary
tube is often employed to control the flow of refrigerant. This
method of control is generally acceptable to control the flow of
refrigerant in common applications. Indeed, most dehumidifiers are
optimized to perform at 80.degree. F. and 60% relative humidity, a
standard set by the association of Home Appliance Manufacturers.
However, atmospheric conditions around a portable dehumidifier
positioned in an area being dried after water exposure often vary
from this optimum condition, which results in system
inefficiencies. It is thus desirable to optimize performance of a
dehumidifier to employ sensors to monitor temperature and relative
humidity of the incoming atmospheric conditions and the
dehumidified air.
[0006] The following describes a dehumidifying system that employs
a sensor-based system for altering the refrigerant flow in response
to external environmental factors.
SUMMARY OF THE INVENTION
[0007] It is one aspect of a present invention to provide a
dehumidifier that employs a plurality of sensors coupled with a
thermal expansion valve ("TEV") instead of a capillary tube to
control refrigerant to flow through the dehumidifier. One
embodiment of the present invention employs sensors at the inlet
and exhaust locations of the dehumidifier to monitor temperature
and relative humidity of the incoming and dehumidified air. A
micro-processor evaluates data received from the sensors to
determine the appropriate air velocity generated by a fan for
maximum performance. More specifically, depending on the needs of
the system, the micro-processor is capable of adjusting the flow of
air through the dehumidifier by a means of a motor speed
controller, etc., a variable related to performance. As one of
skill will appreciate, an efficient heat exchange must occur in
order for the system to successfully remove humidity from the air
regardless of atmospheric condition. This is especially true when
the system operates in areas of lower ambient humidity that water
restoration dehumidifiers are typically expected to operate.
[0008] In one related embodiment, the TEV is a self-adjusting
metering device that controls the refrigerant gas flow to the
evaporator. When the dehumidifier is operated at different ambient
conditions, the expansion valve responds by opening automatically
to provide additional refrigerant. For example, if the ambient
temperature is higher than normal, the temperature within the
evaporator is restored quickly and efficiently by an increase of
refrigerant flow. After the evaporator reaches the proper
temperature, the TEV will reduce refrigerant flow. Conversely,
capillary tubes of the prior art provide a continuous flow of
refrigerant regardless of the ambient conditions and are thus very
inefficient.
[0009] Another advantage of using a TEV to control refrigerant flow
is the ease of service. More specifically, dehumidifiers that
employ capillary tubes require periodic charging with refrigerant
gas. If the capillary tube system is not charged precisely, for
example, within an ounce of the manufacturer's specification, it
will not operate properly. Such precision is not needed when a TEV
is employed because it selectively alters refrigerant flow based on
the ambient conditions. Variations in operating conditions will be
automatically compensated by the TEV to effectuate efficient
operations.
[0010] In one embodiment the TEV employs an orifice for the
refrigerant flow. The TEV of another embodiment senses the pressure
of the refrigerant coming into the evaporator, as well as, the
temperature of the refrigerant as it exits the evaporator, then
selectively meters the flow of refrigerant into the evaporator. The
metering of refrigerant using the pressure of the refrigerant
entering the evaporator, as well as, the temperature of the
refrigerant as it exits the evaporator assists in moisture grain
depression below that of a standard capillary tube dehumidifier
system. Moisture grain depression is generally a measurement of
water removal from a dehumidification process calculated by
subtracting the moisture content of the air exiting the
dehumidifier from the moisture content of the air entering the
dehumidifier. One of skill in the art will appreciate that the TEV
may receive sensor data associated with other components of the
refrigerant cycle. For example, information from the processor
an/or sensors may be used to control the function of the TEV.
[0011] It is another aspect of the present invention to provide a
dehumidifier having an automated shut down cycle. More
specifically, condensate taken from the air is collected on the
surface of the evaporator and is deposited via gravity into a
reservoir. The condensate is periodically pumped from the reservoir
when the captured fluid reaches a predetermined level. During shut
down of prior art systems, the compressor is turned off and the
pump is manually activated to purge the reservoir. However, some
condensate will inevitably remain on the surface of the evaporator
and will drip into the reservoir after the initial manual purge
process is complete. The purge process must then be repeated to
fully drain the reservoir. If the reservoir is not drained, the
contents thereof may spill when the dehumidifier is moved. One
embodiment of the invention preferably employs a shut down button
which can be utilized to address these problems. Specifically, when
the shut down button is pressed, the compressor is immediately shut
off but the pump and the fan continue to run for a short time
during which the evaporator coil is restored to a temperature above
the dew point which prevents the formation of water thereon. The
pump removes the last of the water from the machine, thereby
eliminating the spillage problem when the machine is moved. A light
may be employed to indicate when the purge process is complete.
[0012] As described above, the pump may also be timer-based.
Alternatively, the pump may be sensor-based wherein the pump is
activated when the level of the collected water in the reservoir
reaches a predetermined level. The reservoir would not need to be
removed to be emptied, as the pump would run on a timer circuit
when the machine is in shut down mode to ensure that the last of
the water is removed from the system.
[0013] The reserve pump of one preferred embodiment also possesses
a "safety factor." For example, if in a worst case the dehumidifier
were to produce two gallons per hour of condensate, the pump would
be rated at six gallons per hour pumping capacity and the timing
circuit would operate the pump for twenty seconds each minute to
remove the water. Should the amount of water produced be less than
the maximum expected, the pump can safely run dry for the expected
short period of about twenty seconds per minute or less.
[0014] One embodiment of the present invention addresses the
lingering fluid issue by employing an automated shut down cycle
that turns off the compressor for a pre-determined amount of time,
thereby allowing the condensate to drip from the evaporator. The
preferred invention also allows the air mover, i.e. a fan, to
remove the maximum amount of condensate possible from the surface
of the evaporator into the condensate reservoir. During the final
seconds of the automatic shut down cycle, the pump of the system
will be activated to ensure that the reservoir is empty and the
internal components of the dehumidifier have been substantially
purged of condensate. Such a system may only require one button to
turn on and off. In the event that a shut down cycle needs to be
canceled and the dehumidifier turned on, pressing the button again
will reactivate the compressor and cancel the shut down cycle.
After the shut down is complete, the machine is ready to be
reactivated by pressing the button.
[0015] It is another aspect that a present invention to employ a
micro channel condenser that functions similar to a traditional
fin/tube heat exchanger but is smaller, lighter and requires less
refrigerant charge. Micro channel condensers are more durable and
not generally damaged by high pressure washers (which may be used
to clean the dehumidifier) that often damage components employing
fins/tubes. Furthermore, micro channel condensers are often
fabricated of aluminum, as opposed to steel, copper, etc., which
reduces weight and size of the overall system and improves
refrigeration system efficiencies as quicker temperature response
times are achieved.
[0016] It is another aspect that a present invention to provide a
dehumidifier having a pre-cooler. More specifically, one embodiment
of the present invention employs a pre-cooler that is generally a
heat exchanger that employs a fan that directs cooler air through
the evaporator, thereby reducing the temperature of the refrigerant
flowing therethrough to more efficiently chill the evaporator and
pull condensation from the intake air.
[0017] It is another aspect that a present invention to provide a
dehumidifier with a removable housing. In one embodiment, the
housing is split along an axis associated with the evaporator so
that removal of the housing exposes the evaporator. The housing
also provides easy access to the other internal components of the
device to facilitate cleaning and/or replacement thereof.
Furthermore, the housing defines an internal shroud that serves as
both an internal duct that directs air to the condenser and
evaporator and provides a location for the condensate
reservoir.
[0018] It is thus an aspect of embodiments of the present invention
to provide a portable dehumidifier, comprising: a housing having an
inlet opening for receiving air of a first humidity and an exit
opening for expelling air of a second humidity; an evaporator
positioned adjacent to said inlet opening, said evaporator having
an inlet tube and an outlet tube; a compressor interconnected to
the evaporator via a outlet tube of the evaporator, the compressor
having an exit tube; a condenser interconnected to the exit tube of
the compressor, the condenser having an exit tube that is
interconnected to a thermal expansion valve that is also associated
with the inlet tube of the evaporator; a sensor associated with the
exit tube of the evaporator; and wherein the sensor communicates
with the thermal expansion valve to control flow of refrigerant
flowing through the evaporator, compressor, compressor and/or
associated tubes.
[0019] It is another aspect of the present invention to provide a
dehumidifier, comprising: an evaporator; a compressor associated
with the evaporator; a condenser associated with the compressor; a
valve associated with the condenser and the evaporator; a sensor
that is associated with the valve; and wherein the sensor
communicates with the valve to control flow of refrigerant through
the portable dehumidifying system.
[0020] It is a further aspect of some embodiments of the present
invention to provide a dehumidifier including a compressor for
delivering hot compressed refrigerant, a condenser that receives
refrigerant from said compressor and condenses same, an expansion
device that receives refrigerant from said condenser and expands
same, an evaporator that receives refrigerant from the expansion
device and evaporating same and delivers the refrigerant to the
compressor, the refrigerant being circulated from said compressor
to said condenser to said expansion device to said evaporator and
back to said compressor in a refrigeration cycle, the improvement
comprising: a sensor associated with the evaporator that
communicates with the expansion device to control the flow of
refrigerant through the dehumidifier.
[0021] It is another aspect of the invention to provide a method of
controlling flow of refrigerant through a system employing a
refrigeration cycle that employs an evaporator, a compressor
interconnected to the evaporator via a first tube, a condenser
interconnected to a valve via a second tube and to the compressor
via a third tube, a forth tube interconnects the valve to the
evaporator and a sensor that is associated with the valve and
associated with the fourth tube, comprising: sensing information
related to at least one of temperature and humidity; and
controlling with the valve the flow of refrigerant through the
first, second, third and fourth tubes and the compressor, condenser
and evaporator.
[0022] The Summary of the Invention is neither intended nor should
it be construed as being representative of the full extent and
scope of the present invention. Moreover, references made herein to
"the present invention" or aspects thereof should be understood to
mean certain embodiments of the present invention and should not
necessarily be construed as limiting all embodiments to a
particular description. The present invention is set forth in
various levels of detail in the Summary of the Invention as well as
in the attached drawings and the Detailed Description of the
Invention and no limitation as to the scope of the present
invention is intended by either the inclusion or non-inclusion of
elements, components, etc. in this Summary of the Invention.
Additional aspects of the present invention will become more
readily apparent from the Detail Description, particularly when
taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The accompanying drawings, which are incorporated in and
constitute a part of the specification, illustrate embodiments of
the invention and together with the general description of the
invention given above and the detailed description of the drawings
given below, serve to explain the principles of these
inventions.
[0024] FIG. 1 is a schematic of a dehumidifier of one embodiment of
the present invention that employs a fin/tube evaporator and a
micro channel condenser;
[0025] FIG. 2 is a schematic of a dehumidifier of one embodiment of
the present invention that employs a fin/tube evaporator and a
micro channel condenser;
[0026] FIG. 3 is a schematic of a dehumidifier of one embodiment of
the present invention that employs a micro channel evaporator and a
micro channel condenser;
[0027] FIG. 4 is a schematic of a dehumidifier of one embodiment of
the present invention that employs a micro channel evaporator and a
micro channel condenser;
[0028] FIG. 5 is a schematic of a dehumidifier of one embodiment of
the present invention that employs a fin/tube evaporator and a
fin/tube condenser;
[0029] FIG. 6 is a schematic of a dehumidifier of one embodiment of
the present invention that employs a fin/tube evaporator and a
fin/tube condenser;
[0030] FIG. 7 is a schematic of a dehumidifier of one embodiment of
the present invention that employs a fin/tube evaporator, a micro
channel condenser and an evaporator pre-cooler;
[0031] FIG. 8 is a schematic of a dehumidifier of one embodiment of
the present invention that employs a fin/tube evaporator, a micro
channel condenser and an evaporator pre-cooler;
[0032] FIG. 9 is a schematic of a dehumidifier of one embodiment of
the present invention that employs a micro channel evaporator, a
micro channel condenser and an evaporator pre-cooler;
[0033] FIG. 10 is a schematic of a dehumidifier of one embodiment
of the present invention that employs a micro channel evaporator, a
micro channel condenser and an evaporator pre-cooler;
[0034] FIG. 11 is a schematic of a dehumidifier of one embodiment
of the present invention that employs a fin/tube evaporator, a
fin/tube condenser and an evaporator pre-cooler;
[0035] FIG. 12 is a schematic of a dehumidifier of one embodiment
of the present invention that employs a fin/tube evaporator, a
fin/tube condenser and an evaporator pre-cooler;
[0036] FIG. 13 is a schematic of a dehumidifier of one embodiment
of the present invention that employs a fin/tube evaporator and a
fin/tube condenser;
[0037] FIG. 14 is a schematic of a dehumidifier of one embodiment
of the present invention that employs a fin/tube evaporator and a
micro channel condenser; and
[0038] FIG. 15 is a schematic of a dehumidifier of one embodiment
of the present invention that employs a micro channel evaporator
and a micro channel condenser.
[0039] FIG. 16 is a front elevation view of one embodiment of the
present invention;
[0040] FIG. 17 is a left elevation view of FIG. 16;
[0041] FIG. 18 is a right elevation view of FIG. 16;
[0042] FIG. 19 is a view of the embodiment shown in FIG. 16 wherein
portions of a housing have been removed for clarity;
[0043] FIG. 20 is a cross-sectional view of FIG. 19;
[0044] FIG. 21 is a top plan view of FIG. 19;
[0045] FIG. 22 is a simplified perspective exploded view showing
the interior components employed by one embodiment of the present
invention; and
[0046] FIG. 23 is a simplified perspective exploded view of the
exterior components employed by embodiments of the present
invention.
[0047] To assist in the understanding of one embodiment of the
present invention the following list of components and associated
numbering found in the drawings is provided herein:
TABLE-US-00001 # Component 2 Dehumidifier 6 Fin/tube evaporator 10
Micro channel condenser 14 Compressor 18 Tubing 22 Thermal
Expansion Valve (TEV) 26 Fan 28 Air 30 Evaporator refrigerant exit
temperature sensor 34 Exit Temperature and/or humidity sensor 38
Intake temperature and/or humidity sensor 42 Micro channel
evaporator 46 Fin/tube condenser 50 Pre-cooler 54 Cooled air 58 Fan
62 Air-to-air heat exchanger 66 Housing 70 Intake 78 Bottom surface
82 Handle 86 Wheel 90 Channel 94 Storage tank 98 Frame 102 Air flow
deflector 106 Back plate 110 Cap 114 Lid 118 Aperture 122
Filter
[0048] It should be understood that the drawings are not
necessarily to scale. In certain instances, details that are not
necessary for an understanding of the invention or that render
other details difficult to perceive may have been omitted. It
should be understood, of course, that the invention is not
necessarily limited to the particular embodiments illustrated
herein.
DETAILED DESCRIPTION
[0049] Referring now to FIGS. 1 and 2, one embodiment of the
dehumidifier 2 is shown that includes a fin/tube evaporator 6, a
micro channel condenser 10, a compressor 14 and related tubing 18
connecting those components. In addition, a thermal expansion valve
(TEV) 22 is associated with the tubing 18 that connects the
evaporator 6 to the condenser 10.
[0050] In operation, a fan 26 draws air 28 into the dehumidifier 2
wherein warm, humid air passes over the fins and tubes of the
evaporator 6. Refrigerant within the evaporator 6 then is heated,
exits the evaporator 6, and is directed to the TEV 22. The
refrigerant directed to the TEV 22 is of a greater temperature as
result of its heat transfer from the intake air. The temperature of
the refrigerant exiting the evaporator 6 is related to varying
ambient conditions and is monitored by a sensor 30. Warm vaporized
refrigerant is directed to the compressor 14 that compresses the
refrigerant and directs it to the condenser 10. Air exiting the
evaporator 6 is also directed to the condenser 10. The condenser
10, then, turns hot vaporized refrigerant into liquid as cool air
from the evaporator 6 picks up heat from the refrigerant. The now
cooled refrigerant is directed from the condenser 10 to the TEV 22
to be expanded into low pressure fluid that receives heat from the
incoming air. The TEV is associated with a sensor 30 such that it
meters the flow of refrigerant to the evaporator 6 based on the
exit temperature sensed. More specifically, the higher the
temperature expelled by the evaporator 6 the more heat transfer is
needed, thus, the flow of refrigerant is increased by the TEV 22.
Conversely, the lower the ambient temperature the less heat
transfer is needed and flow is reduced by the TEV 22.
[0051] The input sensor 38 and the exit sensor 34 measure
temperature and relative humidity of the inlet and exhaust air
flow. Data taken from the sensors is fed to a processor/radio
(P/R), which employs an internal clock, that also receives
information associated with the electrical current (amps) being
drawn by the dehumidifier 2. The water level in the storage tank 94
(see FIG. 20) is also monitored. A thermocouple that senses
temperature at the evaporator 6 communicates with the P/R.
[0052] The P/R of embodiments of the present invention controls the
compressor 14, the condensate pump and the main fan 26. The data
collected by the sensors is used to calculate the Grains per Pound
(GPP) of the input and output air flow. The data is also used to
calculate the performance of the dehumidifier 2, is combined with
electrical current used by the dehumidifier 2 to calculate system
efficiency, is used to calculate ideal fan 26 speed, is used by the
P/R to adjust the fan speed, etc.
[0053] Further, during system shut down, the P/R can run the fan 26
for an extra amount of time to clear the water deposited on the
evaporator 6. The condensate pump will also be triggered by the P/R
to empty all captured condensate from storage tank 94. The P/R can
shut down the machine if it senses the water level in the storage
tank 94 is too high.
[0054] In addition, the P/R can shut down the compressor 14, but
continue to run the fan 26 if it senses that the evaporator 6 is
frozen, which is known as a defrost cycle. During the defrost
cycle, the P/R will not turn the compressor 14 on until a threshold
temperature is reached, at which time the P/R starts a clock to
delay compressor start up to provide extra time for the
dehumidifier 2 to fully defrost. This contemplated process
eliminates the need for the dehumidifier 2 to cycle on and off due
to thawing and re-frosting.
[0055] The P/R may output information to a display located on the
dehumidifier's control panel and may output data and information to
an operator by way of RF or WiFi transmission. The displayed
information may include: input and output temperature and relative
humidity of the air flow, current (amps) drawn by the machine,
input and output GPP, dehumidifier performance, dehumidifier
efficiency, time in defrost mode, visual and audio alarms
associated with a storage tank overfill situation, visual and audio
alarms associated with overheating or malfunctioning components,
and the speed of the fan.
[0056] Referring now to FIGS. 3 and 4, yet another embodiment of
the dehumidifier 2 is shown that is similar to that shown in FIG.
1, wherein a micro channel evaporator 42 is employed instead of a
fin/tube evaporator.
[0057] Referring now to FIGS. 5 and 6 a dehumidifier 2 of another
embodiment of the present invention is shown. This embodiment of
the present invention employs a fin/tube condenser 46 along with a
fin/tube evaporator 6 and is similar to that shown in FIG. 1.
[0058] Referring now to FIGS. 7 and 8 a dehumidifier 2 that employs
a pre-cooler 50 is shown. Here, the fin/tube evaporator 6 receives
cooled air 54 from the pre-cooler assembly 50. The pre-cooler
assembly 50 includes a series of fins and tubes that pull air with
a fan 58 into the fin/tube evaporator 6. The coolant within the
fins and tubes of the evaporator 6 is thus, cooler and water 46 is
more efficiently collected by the evaporator 6.
[0059] Referring now to FIGS. 9 and 10, yet another embodiment of
the present invention that employs a pre-cooler 50 is shown. This
embodiment is similar to that shown in FIG. 7 wherein a micro
channel evaporator is employed.
[0060] Referring now to FIGS. 11 and 12, another embodiment of the
present invention is provided that employs a pre-cooler 50 that is
similar to that described above with reference to FIGS. 4 and 5.
The dehumidifier 2 shown employs a fin/tube condenser 46 and
fin/tube evaporator 6.
[0061] Referring now to FIG. 13, another dehumidifier 2 that
employs a pre-cooler of an alternator configuration is shown. Here,
the fin/tube evaporator 6 receives air 54 from an air-to-air heat
exchanger assembly 62. The air-to-air heat exchanger assembly 62
includes a series of plates connected at alternating ends to allow
air to flow in two directions (vertical and horizontal). The
incoming air 28 is cooled via convective methods by the air exiting
the evaporator 6.
[0062] Referring now to FIG. 14, yet another embodiment of the
present invention that employs an air-to-air heat exchanger 62.
This embodiment is similar to that shown in FIG. 13, but employs a
micro channel condenser 10.
[0063] Referring now to FIG. 15 another embodiment of the present
invention is provided that employs an air-to-air pre-cooler 62. The
dehumidifier 2 shown employs a micro channel condenser 10 and a
micro channel evaporator 46.
[0064] FIGS. 16-18 show one embodiment of the present invention
that employs a housing 66 that encloses the internal components.
The housing 66 employs an intake 70 that receives air and an
exhaust that expels dryer air from a bottom surface 78 of the
dehumidifier 2. In order to facilitate movement of the dehumidifier
2, a handle 82 and at least two wheels 86 are provided. Embodiments
of the present invention are about 341/2 inches tall (H), 201/2
inches wide (W) and about 23 inches long (L).
[0065] Referring now to FIGS. 19-21, the arrangement of the
internal components of one embodiment of the present invention is
shown. Air 28 is received within the dehumidifier 2 through the
heat exchanger 62 that cools the incoming air. The cooled air is
then introduced to the evaporator 6, which further cools the air by
heat transfer to the cold fluid running therethrough. Although a
fin/tube evaporator 6 is shown, one of skill in the art will
appreciate that a micro channel evaporator may be employed. The
cooling of the humid air condenses trapped water on the evaporator
that drips from the evaporator 6 onto a channel 90 that leads to a
storage tank 94. The drier air is directed across a condenser 46 as
described above and exits out from the bottom surface 78 of the
dehumidifier 2. Although a fin/tube condenser 46 is shown, one of
skill in the art will appreciate that a micro channel condenser may
be employed. The storage tank 94 of one embodiment of the present
invention is removable to facilitate emptying. Further, as
described above, it is contemplated that pumps that are used to
circulate refrigerant through the evaporator 6 and the condenser 46
run for a time after the dehumidifier 2 is turned off so as to
ensure that all of the water collected by the evaporator 6 is
transferred to the storage tank 94. As can be ascertained by the
arrows presented on the drawing, the housing 66 acts to channel air
through the heat exchanger 62 and other components.
[0066] FIG. 22 shows an interior component arrangement employed by
one embodiment of the present invention. Here, a frame 98 is
employed that secures an air flow deflector 102, condenser 46, the
evaporator 6, the compressor 14 and air to air heat exchanger 42.
The housing 66 envelops the components and ensures proper air flow
through the evaporator 6 and the condenser 46. In order to
facilitate such air flow, the air flow deflector 102 may be
employed.
[0067] Referring now to FIG. 23, the housing 66 and associated
components are shown. Here, the housing 66 is a generally three
sided structure that cooperates with a back plate 106 to create an
air channel. The housing is sealed with a cap 110 and a lid 114.
The lid 114 has an aperture 118 for receiving humid air that is
directed into the internal components of the dehumidifier. Some
embodiments of the present invention employ an inlet filter 122
between the lid 114 and the cap 110 to ensure that particulate
matter does not impede air flow through the heat exchanger or other
components. As mentioned above, the dehumidifier is easily moved as
it is associated with at least two wheels 86 and a handle 82.
[0068] While various embodiments of the present invention have been
described in detail, it is apparent that modifications and
alterations of those embodiments will occur to those skilled in the
art. However, it is to be expressly understood that such
modifications and alterations are within the scope and spirit of
the present invention, as set forth in the following claims.
Further, the invention(s) described herein is capable of other
embodiments and of being practiced or of being carried out in
various ways. In addition, 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.
* * * * *
References