U.S. patent application number 13/182307 was filed with the patent office on 2013-01-17 for evaporative cooling system installed in a structure wall.
The applicant listed for this patent is Paul Gass, Jon Shrader. Invention is credited to Paul Gass, Jon Shrader.
Application Number | 20130014531 13/182307 |
Document ID | / |
Family ID | 47518131 |
Filed Date | 2013-01-17 |
United States Patent
Application |
20130014531 |
Kind Code |
A1 |
Gass; Paul ; et al. |
January 17, 2013 |
EVAPORATIVE COOLING SYSTEM INSTALLED IN A STRUCTURE WALL
Abstract
An evaporative cooling system includes a housing that fits
between a pair of wall studs of a structure. The housing includes a
water pump, an evaporative pad, a water distributor, a motor, and a
fan. In an embodiment, the wall studs are spaced about sixteen
inches on center. This leaves about 14.5 inches between the studs,
and the housing will preferably be about 14 inches in width to
ensure proper fit. The unit may be about 3 to 6 inches in thickness
and about 24 inches in height, protruding no more than about three
inches from the inside wall. The housing also preferably includes a
front cover. A ventilation grill can be installed on the exterior
wall to facilitate outside air being brought into the system. In
other embodiments, the studs are spaced differently (e.g., about
twenty-four inches on center) or the unit is installed in a
structure built using non-wood framing (e.g., SIP, ICF).
Inventors: |
Gass; Paul; (Goodyear,
AZ) ; Shrader; Jon; (Clovis, NM) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Gass; Paul
Shrader; Jon |
Goodyear
Clovis |
AZ
NM |
US
US |
|
|
Family ID: |
47518131 |
Appl. No.: |
13/182307 |
Filed: |
July 13, 2011 |
Current U.S.
Class: |
62/259.4 |
Current CPC
Class: |
F24F 5/0035 20130101;
Y02B 30/545 20130101; F24F 1/0007 20130101; F24F 2221/17 20130101;
Y02B 30/54 20130101; F24F 2006/046 20130101; F24F 6/04
20130101 |
Class at
Publication: |
62/259.4 |
International
Class: |
F28D 5/00 20060101
F28D005/00; F24H 9/00 20060101 F24H009/00 |
Claims
1. A cooling system installable within a structure wall,
comprising: in a housing, the housing disposed between a pair of
studs of the wall, a water reservoir; a pump; a pad; a water
distributor; a motor; and a fan.
2. The cooling system of claim 1, wherein the studs are spaced
about sixteen inches on center.
3. The cooling system of claim 1, wherein the studs are spaced
about twenty-four inches on center.
4. The cooling system of claim 1, wherein the pump brings water
from the water reservoir to the water distributor and the water
distributor distributes the water to the pad thereby moistening the
pad.
5. The cooling system of claim 4, wherein the fan causes air to
flow through the pad moistened by the water, thereby cooling the
air by evaporation.
6. The cooling system of claim 5, wherein the fan causes the cooled
air to flow through an opening.
7. The cooling system of claim 4, wherein at least some of the
water flows back to the reservoir for recirculation.
8. The cooling system of claim 1, wherein the water reservoir is
filled with additional water when the water in the reservoir falls
below a predetermined level.
9. The cooling system of claim 8, further including a ball float
valve that opens to fill the water reservoir with the additional
water when the water in the reservoir falls below the predetermined
level.
10. The cooling system of claim 1, further including a water
drain.
11. The cooling system of claim 1, wherein the housing includes a
front cover.
12. The cooling system of claim 1, wherein the housing protrudes
from the wall less than three inches.
13. The cooling system of claim 1, wherein the wall is a
load-bearing wall.
14. The cooling system of claim 1, wherein the structure is a
garage.
15. A cooling system kit, comprising: the cooling system of claim
1; mounting elements; and a ventilation grill.
16. The cooling system kit of claim 15, further including
instructions.
17. A cooling system, comprising: in a means for mounting within a
structure wall, a means for evaporatively cooling an indoor
area.
18. The cooling system of claim 17, wherein the means for mounting
includes placing the means for evaporatively cooling between wall
studs spaced about sixteen inches on center.
19. The cooling system of claim 17, wherein the means for mounting
includes placing the means for evaporatively cooling within a
structure wall, the structure wall constructed using one of
structural insulated panels (SIP) and insulating concrete forms
(ICF).
20. The cooling system of claim 17, wherein the means for enclosing
protrudes from the wall less than three inches.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to the field of evaporative
coolers, and, more particularly, to an evaporative cooling system
installed in a structure wall.
BACKGROUND
[0002] Evaporative coolers are well known in the prior art. For
example, U.S. Pat. No. 838,602 to Zellweger, issued in 1906,
discloses an evaporative cooling system that used wood chips for
the evaporative media and reportedly cooled the air by as much as
20 degrees. By the middle part of the 20.sup.th Century typical
designs for evaporative coolers included a water reservoir, a pump
to circulate water over evaporative pads, and an electric blower to
draw outside air through the pads, cooling the air by
evaporation.
[0003] Today, many different types of evaporative coolers exist.
Some evaporative coolers are mounted outside a dwelling and are
used to cool the entire interior of the structure. Other
evaporative coolers are used to cool smaller areas such as
individual rooms. Window-mounted units are available but are bulky
and protrude from the exterior of the structure which makes them
unattractive and unacceptable to many homeowner associations. Also,
such window units require an available window. Portable evaporative
coolers include a set of wheels which allow them to be brought into
a room to be cooled. However, such portable evaporative coolers can
take up needed space, and require the user to periodically re-fill
the tank with water. Moreover, portable evaporative coolers do not
bring in fresh outside air. Instead, they continually recirculate
interior air which decreases comfort and inhibits the ability to
cool.
SUMMARY OF THE INVENTION
[0004] According to a preferred embodiment of the present
invention, an evaporative cooling system includes a housing that
fits between a pair of wall studs of a structure. The housing
includes a water pump, an evaporative pad, a water distributor, a
motor, and a fan. In an embodiment, the wall studs are spaced about
sixteen inches on center. This leaves about 14.5 inches between the
studs, and the housing will preferably be about 14 inches in width
to ensure proper fit. The unit may be about 3 to 6 inches in
thickness and about 24 inches in height, protruding no more than
about three inches from the inside wall. The housing also
preferably includes a front cover. A ventilation grill can be
installed on the exterior wall to facilitate outside air being
brought into the system. In other embodiments, the studs are spaced
differently (e.g., about twenty-four inches on center) and the
dimensions may vary to accommodate the spacing. In still other
embodiments, the evaporative cooling system of the present
invention is installed in walls constructed using other
construction methods, such as structural insulated panels (SIP),
insulating concrete form (ICF), etc.
[0005] In operation, the water pump brings water from the water
reservoir to the water distributor and the water distributor
distributes the water to the evaporative pad thereby moistening the
pad. The fan causes an air path whereby relatively warmer outside
air flows through the pad moistened by the water, thereby cooling
the air by evaporation. The cooled air then flows through an
opening in the front cover. Air can enter the evaporative cooling
system from a vent in the back of the cooler open to the outside.
At least some of the water will flow back to the water reservoir
for recirculation. The cooling system further includes a ball float
valve that opens to fill the water reservoir with the additional
water when the water in the reservoir falls below a predetermined
level. The cooling system further includes an overflow drain which
regulates the quantity of water in the water reservoir and allows
excess water to be channeled directly to the drain which relieves
outside of the structure.
[0006] These and other aspects, features, and advantages of the
present invention will become apparent from the following detailed
description of preferred embodiments, which is to be read in
connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 shows a perspective view of an evaporative cooling
system installed in a structure wall, according to a preferred
embodiment of the present invention;
[0008] FIG. 2 shows another view of the evaporative cooling
system;
[0009] FIG. 3 shows a view of the evaporative cooling system with
the front cover removed;
[0010] FIG. 4 shows a side view of the evaporative cooling system;
and
[0011] FIG. 5 shows an exterior view of the structure with a
ventilation grill installed.
DETAILED DESCRIPTION
[0012] FIG. 1 illustrates a perspective view of an evaporative
cooling system 100 installed in a structure wall 140, according to
a preferred embodiment of the present invention. As shown, the
evaporative cooling system 100 includes a front cover 130 which
provides access to user controls 106. When the evaporative cooling
system 100 is operated, cool air is blown from the evaporative
cooling system 100 through an air opening 135 in the front cover
130 to the interior of the room. The present evaporative cooling
system 100 is particularly well suited for cooling a garage but may
be used in other structures as well.
[0013] FIG. 2 shows another view of the evaporative cooling system
100. As shown, the evaporative cooling system 100 is supplied with
water from water supply 180, and includes an overflow drain 190
which allows excess water to be channeled directly to the drain
which relieves outside of the structure. Electric power is supplied
by electric wiring 170 which preferably will be standard 120 V AC
current.
[0014] FIG. 3 shows a view of the evaporative cooling system 100
with the front cover 130 removed for illustrative purposes. As
shown, the evaporative cooling system 100 includes a housing 160
that includes therein the following components: an electric motor
102, a fan 104, the user controls 106 (including an on/off switch
107 and a speed-selection switch 108), a water reservoir 110, a
ball float valve 112, a water pump 114, a water distributor 118, an
evaporative pad 115, and an overflow drain system 195. As shown,
the housing 160 of the evaporative cooling system 100 is disposed
between a pair of wall studs 150. In an embodiment, the wall studs
150 are spaced about sixteen inches on center. This leaves about
14.5 inches between the wall studs 150, and the housing 160 will
preferably be about 14 inches in width to ensure proper fit. The 14
inches allows for there to be approximately 0.25 inches on each
side of the housing 160 between the wall studs 150 in case they are
not exactly centered or if there is a bow in the wall stud 150. In
this embodiment, the housing 160 may be about 4 to 6 inches in
thickness and about 24 inches in height, protruding no more than
about three inches from the inside wall. In other embodiments, the
wall studs 150 will be spaced differently and/or the thickness of
the wall studs 150 will be different (e.g., 2.times.6 inch studs).
In one embodiment the wall studs 150 will be spaced 24 inches on
center leaving a space of 22.5 inches to accommodate the housing
160, so that the housing 160 can be made wider in this case. In
2.times.6 construction, the wall studs 150 would be 5.5 inches deep
and the drywall would be 1/2 inch, so the housing 160 would not
protrude from the structure wall 140 as much (or at all) as in the
case of 2.times.4 inch wall studs 150.
[0015] It is to be appreciated that although discussion has been
limited to traditional wood framing techniques, the evaporative
cooling system 100 of the present invention can also be installed
in walls constructed using other construction methods, such as
structural insulated panels (SIP), insulating concrete form (ICF),
etc. As far as SIP construction, a hole could be cut into the
paneling and the foam insulation removed to accommodate the
evaporative cooling system 100, and then the exterior could be cut
just like in a traditional framing situation. In this case, there
would be no studs; the unit would be anchored to the exterior of
the SIP panels which are usually plywood. With ICF, before the
concrete is poured into the walls, a piece of the concrete form
could be cut out and a blank put in its place to accommodate the
evaporative cooling system 100. After the concrete pour, the blank
would be removed. An anchor could be disposed in the concrete, or
the unit could alternatively be mounted using a wall fastening
system or a wood frame, for example.
[0016] In operation, the water pump 114 brings water from the water
reservoir 110 to the water distributor 118, and the water
distributor 118 distributes the water to the evaporative pad 115
thereby moistening it. The fan 104, which is oriented to blow air
into the room, creates an air path (as illustrated in FIG. 4)
whereby relatively warmer/dryer outside air flows into a
ventilation grill 190 (shown from the exterior in FIG. 5), and is
channeled to the evaporative pad 115, thereby cooling the air by
evaporation. The cooled air then flows through an opening 135 in
the front cover 130. At least some of the water from the
evaporative pad 115 will fall back to the water reservoir 110 for
recirculation. The evaporative cooling system 100 includes the ball
float valve 112 that opens to fill the water reservoir 110 with the
additional water when the water in the reservoir 110 falls below a
predetermined level. The overflow drain system 195 regulates the
quantity of water in the water reservoir 110 and allows excess
water to be channeled directly to the drain which relieves outside
of the structure.
[0017] As mentioned, the exact dimensions of the evaporative
cooling system 100 will vary depending on the spacing of the wall
studs 150, but can also vary depending on the needs of the user.
For instance, it was found that using a FASCO Transflo Blower (a
"squirrel cage" fan) rated at 115 cubic feet per minute (cfm) was
adequate for cooling a typical garage; however, a more powerful fan
could be used to accommodate a larger cooling area. Furthermore,
the evaporative pad 115 could be increased in size (which might
also involve increasing the height and/or width of the housing
106). The water pump 114 can be a submersible pump rated at about
190 gallons per minute (gpm), for example. The water distributor
118 can be constructed from a piece of one-half inch PVC pipe with
holes drilled therein to allow the water to drip on to the
evaporative pad 115, for example. The overflow drain system 195 can
be a standard overflow for coolers which regulates the quantity of
water in the tank (bottom of unit) and allows excess water to get
channeled directly to a drain which relieves outside. The user
controls 106 can include the on/off switch 107 to turn the unit on
or off, as needed, and a speed-selection switch 108 to set the
speed level for the electric motor 102, which preferably will be a
multi-speed electric motor. Preferably, the evaporative media 115
used will be cellulose-based pads with a honeycomb configuration.
However, other suitable materials, such as, for example, cardboard,
wood wool, and even synthetic materials such as
melamine-formadehyde, may suffice.
[0018] It is to be understood that the present invention may be
used for a variety of cooling situations besides cooling a home or
a garage. For example, the evaporative cooling system may be
installed in a doghouse, a portable toilet, a greenhouse, or a
livestock structure. The evaporative cooling system of the present
invention is also suitable for installation in factories,
warehouses, and storage facilities. It is to be further understood
that although the power source is described as being 120V AC
current, that this is only meant as an example. For example, the
evaporative cooler of the present invention could be powered with
220V AC current. Furthermore, for some installations, such as a
doghouse or a portable toilet, solar panels will preferably be used
to power the evaporative cooling system.
[0019] The evaporative cooling system 100 of the present invention
can be mounted within the wall 140 in many different ways, such as
by providing supports 152 below and atop the unit (along with
appropriate angle bracing). Such supports 152 can be pieces of
2.times.4 wood cut to fit and secured by nails or wood screws.
However, preferably, a flanged piece that attaches to the unit to
cover the sides and attaching to the studs with a set of screws
would be used. In this case, the mounting piece would be
essentially L-shaped and one side would attach to the housing 106
and the other would be parallel to the wall 140 allowing for
securing to the wall studs 150. This would also cover any
irregularities in the cut of the drywall by the installer and
eliminate the need for any drywall repairs. Although not shown, it
is to be understood that many additional features may be included
into the evaporative cooling system of the present invention, such
as, for example a thermostat or timer. Additionally, a sweep could
be employed that would sit below the unit in the wall so that if
there was ever a leak then the water would run out into the
structure where it could be detected rather than just saturate the
wall and cause damage. For example, the sweep could start from
behind the unit about an inch from the bottom and continue down the
wall but sweep out to the front of the drywall. Preferably, the
evaporative cooling system 100 would be sold as a "do it yourself"
kit, the kit including the cooling system, mounting elements, and a
set of instructions. Alternatively, the evaporative cooling system
100 would be built into the structure during construction.
[0020] While this invention has been described in conjunction with
the various exemplary embodiments outlined above, it is evident
that many alternatives, modifications and variations will be
apparent to those skilled in the art. Accordingly, the exemplary
embodiments of the invention, as set forth above, are intended to
be illustrative, not limiting. Various changes may be made without
departing from the spirit and scope of the invention.
* * * * *