U.S. patent application number 13/900236 was filed with the patent office on 2014-01-02 for air conditioner for refuge shelter, system and method.
This patent application is currently assigned to Strata Products Worldwide, LLC. The applicant listed for this patent is Michael Scott Bishoff, Larry Franklin Friend, Logan Andrew Lewis, David Emerson Maust, Russell Lewis Smith. Invention is credited to Michael Scott Bishoff, Larry Franklin Friend, Logan Andrew Lewis, David Emerson Maust, Russell Lewis Smith.
Application Number | 20140000299 13/900236 |
Document ID | / |
Family ID | 48805811 |
Filed Date | 2014-01-02 |
United States Patent
Application |
20140000299 |
Kind Code |
A1 |
Maust; David Emerson ; et
al. |
January 2, 2014 |
Air Conditioner for Refuge Shelter, System and Method
Abstract
An air conditioning system for a mine that operates in a mine
environment. A condenser. A refuge system for protecting users from
a toxic environment. The system comprises a refuge shelter. An
evaporator. A method for cooling a refuge shelter. An inflatable
chamber having an airlock, the airlock includes a tube that extends
from the chamber's outer surface into the chamber's interior.
Inventors: |
Maust; David Emerson;
(Grantsville, MD) ; Lewis; Logan Andrew; (Bruceton
Mills, WV) ; Bishoff; Michael Scott; (Friendsville,
MD) ; Friend; Larry Franklin; (Oakland, MD) ;
Smith; Russell Lewis; (Morgantown, WV) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Maust; David Emerson
Lewis; Logan Andrew
Bishoff; Michael Scott
Friend; Larry Franklin
Smith; Russell Lewis |
Grantsville
Bruceton Mills
Friendsville
Oakland
Morgantown |
MD
WV
MD
MD
WV |
US
US
US
US
US |
|
|
Assignee: |
Strata Products Worldwide,
LLC
Sandy Springs
GA
|
Family ID: |
48805811 |
Appl. No.: |
13/900236 |
Filed: |
May 22, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61690565 |
Jun 28, 2012 |
|
|
|
Current U.S.
Class: |
62/115 ; 137/223;
165/121; 165/163; 429/179; 62/260 |
Current CPC
Class: |
F25D 13/00 20130101;
Y10T 137/3584 20150401; E21F 3/00 20130101; F24F 1/0003 20130101;
E21F 11/00 20130101 |
Class at
Publication: |
62/115 ; 62/260;
165/163; 165/121; 429/179; 137/223 |
International
Class: |
F25D 13/00 20060101
F25D013/00 |
Claims
1. An air conditioning system for a mine that operates in a mine
environment comprising: a rigid shell having a door, which when
open defines an opening; a passive condenser disposed in the shell
alongside the door so when the door is open, the condenser is
exposed to the mine environment; an explosion proof permissible
enclosure disposed in the shell that is isolated from the mine; a
first fluid pump which pumps fluid disposed in the enclosure; a
portable evaporator disposed in the shell; a compressor which pumps
refrigerant; a controller in communication with the evaporator
which controls the evaporator operation; and a battery array
disposed in the shell and electrically connected to the first fluid
pump.
2. The system of claim 1 wherein the condenser is mounted to the
door so an opening at the bottom of the condenser is disposed at
least 1 inch above the ground to allow air to flow through the
opening and to a bottom portion of the condenser.
3. The system of claim 2 wherein the condenser has a chimney
portion having upper fins that guide air flow through them out of
the chimney portion and prevents turbulent flow of the air through
the condenser.
4. The system of claim 3 wherein the condenser is rectangular
shaped.
5. The system of claim 4 wherein the chimney portion has upper fins
that are removable.
6. The system of claim 5 wherein the bottom portion of the
condenser has 4-8 bottom fins per inch.
7. The system of claim 6 including a purge system to isolate the
enclosure from the mine.
8. The system of claim 7 wherein the purge system includes a
pressurized nitrogen bottle disposed in the container in fluid
communication with the enclosure which provides nitrogen gas to the
enclosure and maintains positive pressure in the enclosure.
9. The system of claim 8 including a flame arrestor disposed in a
wall of the enclosure, and tubing connected to the nitrogen bottle
and the arrestor through which the nitrogen gas flows from the
nitrogen bottle through the arrestor into the enclosure.
10. A condenser comprising: a housing; a bottom portion having a
refrigerant coils through which refrigerant flows and bottom fins
which contact the refrigerant coils and which cool the refrigerant
passing through the coils; and a chimney portion disposed above the
bottom portion that draws air into the bottom portion and channels
the air up through the chimney portion.
11. A refuge system for protecting users from a toxic environment
comprising: a refuge shelter; and an air conditioning system in
communication with the shelter, the air conditioning system having
an evaporator disposed in the shelter and a shell disposed outside
and apart from the shelter, the shell having a condenser and a
compressor, the compressor pumping refrigerant to the condenser and
the evaporator through hoses that connect the compressor and the
condenser and the evaporator together in a fluidic loop.
12. The system of claim 11 wherein the shelter has a container and
an inflatable tent that when inflated defines a protected
environment for the users and in which the evaporator is disposed,
the container having pressurized gas tanks that release breathable
air or oxygen into the environment and maintains positive pressure
in the inflated tent relative to an atmosphere outside the
tent.
13. An evaporator comprising: a housing having fins and refrigerant
coils in fluidic communication with the fins through which
refrigerant flows, there being 4-8 fins per inch; a fan disposed in
the housing; and a gas powered motor disposed in the housing to
operate the fans.
14. A method for cooling a refuge shelter comprising the steps of:
connecting refrigerant hoses attached to a compressor and a
condenser in a shell to an evaporator in the shelter, the shell
disposes outside and apart from the shelter; and activating from
the shelter the compressor in the shell which pumps refrigerant to
the evaporator and the condenser.
15. An inflatable chamber having an airlock, the airlock includes a
tube that extends from the chamber's outer surface into the
chamber's interior, the tube having an outer end attached to the
outer surface and an inner end, an outer closure that closes the
outer end and an inner closure that closes the inner end.
16. The chamber of claim 15 wherein the outer closure includes an
outer drawstring that when pulled closes the outer end and the
inner closure includes a zipper at the inner end to open and close
the inner end, and an inner drawstring that when pulled closes the
inner end.
17. A container in an environment comprising: an explosion proof
enclosure isolated from the environment; and a purge system in
communication with the enclosure.
18. An electricity source comprising: a battery having a plate and
a case; and a terminal formed of a cable which extends out of the
case and is welded to the plate.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a non-provisional of U.S. provisional application
Ser. No. 61/690,565 filed Jun. 28, 2012.
FIELD OF THE INVENTION
[0002] The present invention is related to air conditioners for use
with refuge shelters in hazardous environments, such as a mine. As
used herein, references to the "present invention" or "invention"
relate to exemplary embodiments and not necessarily to every
embodiment encompassed by the appended claims.) More specifically,
the present invention is related to air conditioners for use with
refuge shelters in hazardous environments, such as a mine, where a
compressor and a condenser of the air conditioner is located
outside of the refuge shelter and an evaporator of the air
conditioner is located in the refuge shelter and connected to the
compressor and the condenser.
BACKGROUND OF THE INVENTION
[0003] This section is intended to introduce the reader to various
aspects of the art that may be related to various aspects of the
present invention. The following discussion is intended to provide
information to facilitate a better understanding of the present
invention. Accordingly, it should be understood that statements in
the following discussion are to be read in this light, and not as
admissions of prior art.
[0004] In emergency situations where the environment becomes
hazardous to people, a refuge shelter provides a safe protected
environment from the outside hazardous environment. Over time, if
people must stay in the refuge shelter, steps must be taken to
maintain the environment inside the refuge shelter as safe, such as
maintain the carbon dioxide level or the temperature in locations
where heat is an issue and the temperature cannot be maintain at
safe comfortable levels because the outside environment is too warm
to cool the refuge shelter. Furthermore, in certain environments,
such as in coal mines, there is risk of explosion that must be
avoided. Consequently, there is a need for an air conditioner for a
refuge shelter that is safe to use in a mine which will avoid the
possibility of causing an explosion.
BRIEF SUMMARY OF THE INVENTION
[0005] The present invention pertains to an air-conditioning system
for a mine that operates in a mine environment. The system
comprises a rigid container having a door, which when open defines
an opening. The system comprises a passive condenser disposed in
the container alongside the door so when the door is open, the
condenser is exposed to the mine environment. The system comprises
an explosion proof enclosure disposed in the container. The system
comprises a first fluid pump which pumps fluid disposed in the
enclosure. The system comprises a portable evaporator disposed in
the container. The system comprises a compressor which pumps
refrigerant. The system comprises a controller in communication
with the evaporator which controls the evaporator operation. The
system comprises a battery array disposed in the container and
electrically connected to the first fluid pump. The system
comprises a condenser.
[0006] The present invention pertains to a condenser. The condenser
comprises a housing. The condenser comprises a bottom portion
having a refrigerant coils through which refrigerant flows and
bottom fins which contact the refrigerant coils and which cool the
refrigerant passing through the coils. The condenser comprises a
chimney portion disposed above the bottom portion that draws air
into the bottom portion and channels the air up through the chimney
portion.
[0007] The present invention pertains to a refuge system for
protecting users from a toxic environment. The system comprises a
refuge shelter. The system comprises an air conditioner in
communication with the shelter. The air conditioner having an
evaporator disposed in the shelter and a shell disposed outside and
apart from the shelter. The shell having a condenser and a
compressor. The compressor pumping refrigerant to the condenser and
the evaporator through hoses that connect the compressor and the
condenser and the evaporator together in a fluidic loop.
[0008] The present invention pertains to an evaporator. The
evaporator comprises a housing having fins and refrigerant coils in
fluidic communication with the fins through which refrigerant
flows, there being 4-8 fins per inch.
[0009] The present invention pertains to a method for cooling a
refuge shelter. The method comprises the steps of connecting
refrigerant hoses attached to a compressor and a condenser in a
shell to an evaporator in the shelter. The shell disposes outside
and apart from the shelter. There is the step of activating the
compressor which pumps refrigerant to the evaporator and the
condenser.
[0010] The present invention pertains to an inflatable chamber
having an airlock, the airlock includes a tube that extends from
the chamber's outer surface into the chamber's interior, the tube
having an outer end attached to the outer surface and an inner end,
an outer closure that closes the outer end and an inner closure
that closes the inner end.
[0011] The present invention pertains to a container in an
environment. The container comprises an explosion proof enclosure
isolated from the environment. The container comprises a purge
system in communication with the enclosure.
[0012] The present invention pertains to an electricity source. The
source comprises a battery having a plate and a case. The source
comprises a terminal formed of a cable which extends out of the
case and is welded to the plate.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0013] In the accompanying drawings, the preferred embodiment of
the invention and preferred methods of practicing the invention are
illustrated in which:
[0014] FIG. 1A shows an XP enclosure of the air conditioner of the
present invention.
[0015] FIGS. 1B-1D show a layout schematic of the present
invention.
[0016] FIG. 2 is a representation of the refuge system of the
present invention.
[0017] FIG. 3 shows a battery of the present invention.
[0018] FIGS. 4A-4D show different views of the superstructure of
the enclosure.
[0019] FIG. 4E shows the enclosure.
[0020] FIGS. 5A-5C show different views of an arrestor.
[0021] FIG. 6 shows the purge feature of the enclosure.
[0022] FIG. 7 shows the supply hose and the return hose connected
to the fan motor.
[0023] FIG. 8 shows the evaporator fan assembly.
[0024] FIG. 9 shows the evaporator.
[0025] FIG. 10 shows the evaporator.
[0026] FIG. 11 shows the cable bundle with the mini air lock.
[0027] FIG. 12 shows the cable bundle and the mini airlock.
[0028] FIG. 13 shows the cable bundle and the mini airlock.
[0029] FIG. 14 shows a pod of batteries.
[0030] FIG. 15 shows the battery system.
[0031] FIG. 16 shows the hydrogen sensor.
[0032] FIG. 17 shows the methane sensor.
[0033] FIG. 18 shows the control box.
[0034] FIG. 19 shows the status panel.
[0035] FIG. 20 shows the condenser.
[0036] FIG. 21 shows the condenser.
[0037] FIG. 22 shows the condenser.
[0038] FIG. 23 shows the intake side of the condenser.
[0039] FIG. 24 shows the top of the condenser.
[0040] FIG. 25 shows the removable fins of the condenser.
[0041] FIG. 26 is a graph showing battery test results.
[0042] FIGS. 27a-27d show top, side, front and back views,
respectively, of the condenser.
DETAILED DESCRIPTION OF THE INVENTION
[0043] Referring now to the drawings wherein like reference
numerals refer to similar or identical parts throughout the several
views, and more specifically to FIGS. 1A-1D and 2 thereof, there is
shown an air-conditioning system 10 for a mine that operates in a
mine environment. The system 10 comprises a rigid shell 24 having a
door 28, which when open, defines an opening. The system 10
comprises a passive condenser 26 disposed in the shell 24 alongside
the door 28 so when the door 28 is open, the condenser 26 is
exposed to the mine environment. The system 10 comprises an
explosion proof enclosure 22 disposed in the shell 24, as shown in
FIG. 4E. The system 10 comprises a first fluid pump 58 which pumps
fluid disposed in the enclosure 22. The system 10 comprises a
portable evaporator 18 disposed in the shell 24. The system 10
comprises a compressor 38 which pumps refrigerant. The system 10
comprises a controller 102, as shown in FIG. 18, in communication
with the evaporator 18 which controls the evaporator 18 operation.
The system 10 comprises a battery array 19 disposed in the shell 24
and electrically connected to the first fluid pump 58. The system
10 comprises a condenser 26.
[0044] The condenser 26 may be mounted to the door 28 so an opening
at the bottom of the housing 146 is disposed at least 1 inch above
the ground to allow air to flow through the opening and to the
bottom portion 148 of the condenser 26. The condenser 26 may have a
chimney portion 150 having upper fins 156 that guide air flow
through them out of the chimney portion 150 and prevents turbulent
flow of the air through the condenser 26, as shown in FIGS. 20-25.
The housing 146 may have a rectangular shape. The chimney portion
150 has upper fins 156 that are removable. There may be 4-8 bottom
fins 154 per inch.
[0045] The present invention pertains to a condenser 26. The
condenser 26 comprises a housing 15. The condenser 26 comprises a
bottom portion 148 having refrigerant coils 152 through which
refrigerant flows and bottom fins 154 which contact the refrigerant
coils 152 and which cool the refrigerant passing through the coils
152. The condenser 26 comprises a chimney portion 150 disposed
above the bottom portion 148 that draws air into the bottom portion
148 and channels the air up through the chimney portion 150.
[0046] The present invention pertains to a refuge system 15 for
protecting users from a toxic environment, as shown in FIGS. 1A and
2. The system comprises a refuge shelter 12. The system 15
comprises an air conditioning system 10 in communication with the
shelter. The air conditioning system 10 having an evaporator 18
disposed in the shelter and a shell 24 disposed outside and apart
from the shelter. The shell 24 having a condenser 26 and a
compressor 38. The compressor 38 pumping refrigerant to the
condenser 26 and the evaporator 18 through hoses that connect the
compressor 38 and the condenser 26 and the evaporator 18 together
in a fluidic loop.
[0047] The shelter 12 may have a container 84 and an inflatable
tent 82 or chamber that when inflated defines a protected
environment for the users and in which the evaporator 18 is
disposed. The container 84 having pressurized gas tanks that
release breathable air or oxygen into the environment and maintains
positive pressure in the inflated tent 82 relative to an atmosphere
outside the tent 82.
[0048] The present invention pertains to an evaporator 18, as shown
in FIGS. 9 and 10. The evaporator 18 comprises a housing 170 having
fins 172 and refrigerant coils 174 in fluidic communication with
the fins 172 through which refrigerant flows, there being 4-8 fins
172 per inch.
[0049] The present invention pertains to a method for cooling a
refuge shelter 12. The method comprises the steps of connecting
refrigerant hoses 42, 44 attached to a compressor 38 and a
condenser 26 in a shell 24 to an evaporator 18 in the shelter. The
shell 24 disposes outside and apart from the shelter. There is the
step of activating the compressor 38 which pumps refrigerant to the
evaporator 18 and the condenser 26.
[0050] The present invention pertains to an inflatable chamber 82
having an airlock 72, as shown in FIGS. 2 and 11-13. The airlock
includes a tube 83 that extends from the chamber's outer surface
into the chamber's interior. The tube 83 having an outer end 85
attached to the outer surface and an inner end 87, an outer closure
that closes the outer end and an inner closure that closes the
inner end.
[0051] The outer closure may include an outer drawstring 80 that
when pulled closes the outer end and the inner closure includes a
zipper 76 at the inner end to open and close the inner end, and an
inner drawstring 80 that when pulled closes the inner end.
[0052] The present invention pertains to a container in an
environment. The container comprises an explosion proof enclosure
22 isolated from the environment. The container comprises a purge
system 30 in communication with the enclosure 22.
[0053] The present invention pertains to an electricity source. The
source comprises a battery 19 having a plate 35 and a case 36. The
source comprises a terminal 32 formed of a cable 34 which extends
out of the case 36 and is welded to the plate 35.
[0054] In the operation of the invention, the MSHA Approved 96
hour, 24 VDC Air Conditioning System 10, as shown in FIGS. 1A and
2, is battery 21 powered and designed to be used in conjunction
with Refuge Shelters 12 created to provide post event refuge in a
coal mine environment. It is designed to provide 96 hours of
cooling to the shelter occupants in an environment that would
otherwise exceed the MSHA requirement that conditions within Refuge
Shelters 12 must remain under 95 degrees apparent during the 96
hour rated service. At the time of deployment, the miners activate
the system 10, insert a hose and cable bundle 16, as shown in FIGS.
11-13, into the side of the Refuge Shelter 12, and carry the
evaporator 18 cooling unit with them into the shelter 12. After
safely inside the shelter, the miners connect the evaporator 18 to
the bundle 16 inserted earlier and activate the air conditioning
system 10. See U.S. patent application Ser. No. 11/903,079 directed
to a Refuge Shelter 12; U.S. patent application Ser. No.
12/075,002, directed to a scrubber for a Refuge Shelter 12, and
U.S. provisional application directed to a refuge shelter; all of
which are incorporate by reference herein.
[0055] The structural shell 24 of the system 10 is designed to meet
the MSHA CFR 30, Part 7 design requirements for Refuge Shelters 12
which require the structure to withstand a 200 millisecond, 15 PSI
blast. In order to meet that requirement, this system 10 has a
housing of a shell 24 of a Strata Worldwide LLC M10 refuge chamber
currently in production. This shell 24 will be modified slightly to
house the components of the air conditioning system 10. These
modifications include installation of an air tight bulkhead 14 to
separate the components designed to be isolated from the mine
atmosphere and those components designed to be exposed to the mine
atmosphere or those components which will be taken into the Refuge
Shelter 12. The shell 24 will also be modified to accommodate a
sled to contain the batteries 21 and explosion proof (XP) enclosure
22, the door 28 mounted condenser 26 as well as control and display
panels necessary for system 10 operation.
[0056] One of the difficulties in obtaining approval for a system
such as this is that the CFR 30, Part 7 regulations require that
equipment located "inside" the refuge alternative must be IS
(Intrinsically Safe) or permissible while electrical equipment
exposed to the mine environment must be IS. The previous
interpretation of this regulation rendered design of an air
conditioning system 10 virtually impossible due to the level of
energy required to remove the heat generated in an occupied refuge
shelter or alternative. However, it has been determined that MSHA
is of the opinion that the law also allows for permissible
equipment if the equipment is isolated from the mine environment.
It is that interpretation which has allowed the development of a
permissible system due to a unique technique of isolating the
system from the mine environment.
[0057] The isolation system employed by the MSHA Air Conditioning
System 10 uses two means of isolation. First, the components are
housed in a gasketed steel structure, previously referred to as the
shell 24. This structure is vacuum tested to insure the integrity
of the seals, welds, and panels after fabrication. The second means
of isolating the components from the mine atmosphere is a purge
system 30 that releases nitrogen into the XP enclosure 22 creating
a positive pressure environment in the control and power section,
compartment 92, thus forcing out any possible contaminants from the
mine atmosphere and preventing any ingress of methane. See FIG. 4.
This purge system 30 contains bottle(s) 29, as shown in FIG. 1D, of
nitrogen located in the shell 24, one of which is dumped just prior
to activation while the second bottle is released at a slow trickle
over the 96 hour operation of the shell 24. See FIGS. 1B-1D and 2.
Not only does this purge isolate the shell 24 from the mine
atmosphere, the nitrogen creates a nonflammable environment to
eliminate any chance of explosion. The two pressurized nitrogen
bottles are each connected by tubing to frame arrestor 40 in a wall
112 of the XP enclosure 22. Over pressure of nitrogen in the XP
enclosure 22 vents into the interior of the shell 24 through
another flame arrestor 40 in the wall 112 of the XP enclosure 22.
The purge through the enclosure 22 into the shell 24 is great
enough to maintain positive pressure in the shell 24 too. The
bulkhead 14 has two pressure relief valves for nitrogen gas to
escape if pressure in the shell 24 becomes too great. It is this
purge system 30 that has created the scenario where MSHA believes
the shell 24 and the components disposed in it, including the
enclosure 22, may be permissible instead of IS.
[0058] Although MSHA has determined that the system enclosed in the
isolated atmosphere must be permissible, there are a number of
unique designs in the system in order to meet the permissible
criteria.
[0059] First, the battery system 20 must meet a special design as
outlined in CFR 30, Part 7 which discusses the battery 21 restraint
system, required venting, connection systems, etc. The system is
designed to meet these criteria. One of the unique aspects of the
battery 21 connection system is a special battery 21 designed
specifically for this application where the battery 21 terminal 32
is a battery cable 34 that is internally welded to the battery 21
plate that then extends approximately 8'' out of the battery case
36. See FIGS. 3, 14 and 15. This allows a "burned on" connection to
the cables that carry the power to the operating components, in
accordance with CFR 30 Part 7, Subsection C.
[0060] Second, the permissible design requires that all components
such as motors, relays, switches, pumps, etc. must be housed within
an MSHA approved XP enclosure 22. This enclosure 22 is designed to
contain an explosion in the event that explosive gas made its way
into the enclosure 22 and was ignited by a spark from a motor, etc.
This then creates challenges to move power, fluids, gases, etc.
from this XP enclosure 22, necessary for cooling and control, to
the Refuge Shelter 12. MSHA rules require that all components
exposed to the mine atmosphere be IS. For an air conditioning
system 10 to function, it is necessary to remove latent and
sensible heat (temperature and humidity) given off by the occupants
of the Refuge Shelter 12 and that energy must be expelled into the
mine environment. This is accomplished by the evaporation and
compression of refrigerant which is circulated from an evaporator
18 located in the refuge back to the compressor 38 and condenser 26
located in the shell 24 via hoses. Moving the refrigerant out of
the XP enclosure 22 required the design of a flame arrestor 40
which would both freely pass the refrigerant but would also contain
any possible explosion emanating from the XP enclosure 22. This
flame arrestor 40, as shown in FIGS. 5A-5D, is also used to pass
compressed air to and from the refuge for driving an air motor used
to draw air through the evaporator 18, pass refrigerant to and from
the XP enclosure 22, venting heat from the XP enclosure 22, as well
as for the nitrogen purge. Next, since the components external to
an XP enclosure 22 are required to be IS, the condenser 26 that
expels the heat removed from the Refuge Shelter 12 has been
designed to be passive with no fan to force air through the system.
This means the system must be uniquely designed to remove heat via
natural convection. Additionally, the evaporator 18 would be
entirely too large to carry if it were designed to function
passively so a motor, powered by air, was chosen to circulate the
refuge air through the evaporator 18 for cooling.
[0061] Finally, due to the IS requirements, the control system used
to operate the air conditioning system 10 from within the chamber
is a fiber optic design. This control system is designed to allow
the miners to start and stop as well as monitor and reset the
system from within the refuge. See FIG. 18.
[0062] This air conditioning system 10 operates in many ways like a
conventional air conditioner. However, the operating environment
requires unique features, many of which have already been
described. Some additional unique controls include:
[0063] Inside the XP enclosure 22, as shown in FIGS. 2 and 4E, is
disposed a compressor 38 which pumps the refrigerant through a
refrigerant supply hose 42 to the condenser 26 and from the
evaporator 18 through a refrigerant return hose 44 to the
evaporator 18, and then back to the compressor 38 to repeat the
cycle. The refrigerant, as it goes through the refrigerant supply
hose 42 to the evaporator 18, is exposed to the heat inside the
refuge chamber. The refrigerant in the evaporator 18 cools the
refuge air as it passes through the evaporator 18. The refrigerant
flows from the evaporator 18 through the refrigerant return hose 44
to the compressor 38 then to condenser 26 which removes the heat
from the refrigerant that came from the air that was cooled in the
evaporator 18 then the cycle is repeated. In this way, refrigerant
constantly flows through a loop for cooling. There is in the XP
enclosure 22 in communication with the refrigerant supply hose 42
and refrigerant return hose 44 loop, a refrigerant reservoir 46 for
providing additional refrigerant as needed. The XP enclosure 22 is
about 40'' long, 20'' high and 17'' wide. The walls 112 are 3/8''
thick steel and all along the edges are rim bars 111 welded in
place to the two walls forming the edge, with bolt hole in the rim
bars 111 for the cover. See FIGS. 4A-4D.
[0064] The overall operation of the cycling of the refrigerant
through the evaporator 18 and the condenser 26 with the reservoir
46 by the compressor 38 is essentially a standard air-conditioning
unit. However, because of the danger of explosion inside a mine,
extra care has been taken to respect this dangerous environment and
has resulted in the condenser 26 being completely passive in regard
to the air cooling the refrigerant as it flows through the
condenser 26. The compressor 38 is inside the XP enclosure 22
because it requires electricity so if there is a spark or some
potential fire, the XP enclosure 22 contains the damage explosion
or fire can cause. Furthermore, remotely located from the
compressor 38 and condenser 26 is the evaporator 18 which is
located inside the refuge chamber where the miners reside for the
cooling of the air.
[0065] All cables or wiring that extends from the inside of the XP
enclosure 22 to outside the XP enclosure 22 pass through MSHA
approved glands 56. Media flowing through hoses such as the
refrigerant, compressed air or atmospheric gasses flowing to or
from the XP enclosure 22, pass through flame arrestors 40. The
flame arrestors 40 dissipate essentially all of flames associated
with an explosion or fire inside the XP enclosure 22 so by the time
any gas from the fire or explosion exits the flame arrestor 40, the
gas has cooled to a temperature below that which would ignite any
methane in the surrounding environment of the mine.
[0066] The flame arrestor 40, as shown in FIGS. 5a, 5b and 5c, is a
metal element 48, such as a cylinder that has multiple layers of
screens 50 with holes 52 and washers 54 that allow gas or fluid to
flow through them, but slow down the gas or fluid and absorb heat
from the gas or fluid as it passes through the series of screens 50
until it exits the flame arrestor 40, with the fluid or gas then at
a temperature below the temperature needed to ignite methane.
[0067] Each hose, such as the supply and return hose, passes
through the XP enclosure 22 in two parts. The first part, inside
the XP enclosure 22, extends from its component source, such as the
compressor 38, to the portion of a flame arrestor 40 extending into
the XP enclosure 22. The second part, outside the XP enclosure 22,
attaches to and extends from the portion of the flame arrestor 40
extending out from the XP enclosure 22, to the ultimate
destination, for instance, the evaporator 18. In this way, the
fluid in any given hoses safely passes through a wall 112 of the XP
enclosure 22. For cabling, such as the optical fiber, MSHA approved
glands 56, which are well known in the art, are used to allow the
cabling or optical fiber to safely extend through the wall 112 of
the XP enclosure 22 with essentially no risk of explosion or fire
escaping through the aperture that has the cabling or fiber.
[0068] The first and second electric powered air pumps 58, 60
disposed inside the XP enclosure 22, connect to an air supply hose
62 that extends and connects to the evaporator 18, and an air
return hose 64 that extends from the evaporator 18 to the air pumps
58, 60. The air pumps 58, 60 are in parallel so they provide a
redundancy in the pumping of air, and provide increased pressure
and volume to the air that is pumped. The air supply hose 62 and
the air return hose 64 form a closed loop so the air inside the
closed loop constantly circulates around and around never escaping.
This air turns a fan motor 66, such as model Lynx Pro 3 hand piece
manufactured by MTI Dentalin, in communication with the loop. The
fan motor 66 has a shaft 68 that extends from the fan motor 66 and
has a fan 70 at its outer end that is disposed in a fan housing 71.
As the air in the loop moves through the loop, it turns the air
motor, but cannot escape. As the air motor turns, so does the shaft
68, which in turn rotates the fan 70, which forces air in the
Refuge Shelter 12 to pass through the evaporator 18. The air supply
hose 62 and the air return hose 64 have self-closing fittings as is
well known in the art, so that when the ends of either of the air
houses are not connected, but open, the ends automatically close so
no air inside the hoses can escape. In this way, the air present
during their manufacture becomes trapped inside the hoses and is
all that is necessary to be used to circulate through the air loop
and power the air motor to turn the fan 70. The closed loop is an
important design feature in that it prevents introduce contaminants
into the refuge chamber.
[0069] The supply and return hoses for the refrigerant and the air,
and the control cable 74 from the XP enclosure 22 pass into the
refuge chamber through what can be considered a mini airlock 72 in
the tent 82, as shown in FIGS. 11-13. The mini airlock 72 is
essentially a fabric tube about 36 inches long, that extends from
the outer surface of the tent 82 into the interior of the tent 82.
The inside end of the fabric tube has a zipper 76 that closes the
tube face. At the surface of the outside of the tent 82, there is a
tubular section 78 of material that covers the opening of the
fabric tube. There are also drawstrings 80 at either end of the
fabric tube. Upon deployment of the tent 82, the miners take the
hoses and cable from the XP enclosure 22 and extend into the fabric
tube. Once the evaporator 18 is carried into the inflated chamber
of the Refuge Shelter 12, the zipper 76 at the inside end of the
fabric tube is unzipped and the end of the hoses and cable are
pulled through and attached to the appropriate connections of the
evaporator 18. Once the control cable 74 and hoses are in place,
the draw string at either end of the fabric tube is drawn tight
essentially forming a seal at either end around the cable and
hoses. In addition, since positive pressure is maintained inside
the chamber of the inflated tent 82, air from the chamber is
constantly trying to escape outward from the chamber, which
effectively prevents the outside environment from entering into the
chamber.
[0070] The air conditioning system 10 uses a different type of
condenser 26, known as a passive condenser 26, to achieve energy
efficient heat rejection. See FIGS. 20-25. Since the AC is powered
by a battery 21 bank, there is a finite amount of energy that is
available to the system, placing substantial emphasis on energy
efficiency. Traditional condensers use fans to transmit air through
the condenser 26; however, the passive condenser 26 uses no fans,
and relies on natural convection to reject heat. Fans use energy,
and eliminating the fan allows the system to use less energy to
achieve the same result. Furthermore, the passive condenser 26 will
be used in a post-explosion coal mine environment, which can be
potentially filled with methane. The danger is that an electrical
fan could produce a spark that may ignite the methane within the
mine, causing a secondary explosion. Having a condenser 26 that
does not utilize a fan or have any moving parts increases the
energy efficiency of the system and ensures safety in a methane
environment.
[0071] The condenser 26, because it is passive, is much larger than
it otherwise would be if there was air forced about the condenser
26 to cool the refrigerant passing through the condenser 26.
However, because of the danger of an explosion in a mine, by being
a passively operated condenser 26, any risk or threat of explosion
from the operation of the condenser 26 is eliminated. The condenser
26 is positioned at the end of the steel shell 24. The end of the
shell 24 alongside the condenser 26 has a large door 28 which opens
up to the mine environment so the atmosphere of the mine can
contribute to the cooling of the refrigerant passing through the
condenser 26.
[0072] The anatomy of the passive condenser 26 has some fundamental
differences than traditional condensers. First, the passive
condenser 26 uses a flue that enhances the natural airflow through
the coils 152 by the principles of buoyancy; hot air rises through
the flue, pulling cooler air into the intake of the condenser 26.
The flue essentially acts as a duct that forces the hot air to rise
through it similar to that of a chimney in a house. Without the
flue, the natural air flow at the outlet of the condenser 26
becomes turbulent, disrupting the air flow while reducing the
condenser's thermal capacity. This flue is part of the condenser 26
structure, and is not removable. The condenser 26 is bolted to the
door 28 of the shell 24. When the door 28 of the shell 24 is
opened, the condenser 26 is moved into the environment of the mine
and is exposed to the air in the mine. The intake of the condenser
should be at least about 3 inches above ground.
[0073] Second, the "wetted" portion of the coil, which houses the
refrigerant coils 152, is located in the bottom portion 148 of the
condenser 26, heating the incoming air, and causing the air to rise
through the chimney portion 150. An important characteristic of
this portion of the condenser 26 is the fin spacing. Most
condensers utilize about 12-14 fins per inch, which is well suited
for forced convection condensers. However, the passive condenser 26
has only 4-8 and preferably 6 fins 154 per inch to reduce airflow
restriction, which is important due to the passive condenser 26
relying on natural air flow for its heat rejection. This fin 154
spacing is considered quite "open" by industry, and is not typical
of standard condensers.
[0074] Third, the chimney portion 150 of the condenser 26 has
removable fins 156 that provide adjustability to maximize the
condenser's performance. These fins 156 are held in place by sheet
metal screws 158 that can be easily removed; after screw removal
the fin 156 can slide out of the top of the condenser 26. The
utility of this design is that it provides the option to adjust the
condenser's performance by removing fins 156. Each fin 156
segregates the chimney's flow area into smaller chimneys, which
help reduce eddy currents near the outlet of the chimney portion
150. However, with the addition of each fin 156, there is more flow
restriction in the chimney portion 150. Having the capability to
remove fins 156 provides the adjustability needed to find the
correct balance of flow restriction vs. eddy current reduction for
each mine environment the system will be placed into.
[0075] The condenser 26 may be rectangular. The fins 156 are
essential flat sheets of metal. The removable fins 156 also have a
flange 160 at the top that extends from the flat sheet through
which the screw 158 extends to hold the sheet in place. FIGS.
27a-27d show top, side, front and back views, respectively, of the
condenser.
[0076] The evaporator 18, as shown in FIGS. 9 and 10, is also
unique in its design as compared to commercially available
evaporators. The fins are spaced further apart than typical units,
4-8 fins 172 per inch as compared to 12-14 fins per inch, in order
to prevent moisture saturation and "clogging". The evaporator 18
fins 172 may also be coated with a hydrophilic coating or film to
assist in shedding of accumulated water droplets. The application
of a hydrophilic coating or film onto a piece of metal, such as to
form a fin, is well known to one skilled in the art.
[0077] In regard to clogging, when an air conditioner is operated
in a high moisture environment such as is the condition in a refuge
chamber, water droplets accumulate on the fins as the air is
cooled. If the fin spacing is too close, the surface tension of the
water causes the water droplets to cling to the fins and accumulate
to such a degree that the entire evaporator 18 is completely filled
with water and prevents air from flowing through the evaporator 18.
By spreading the fins apart, while the "dry air" efficiency of the
energy transfer is reduced, the force of gravity overcomes the
natural surface tension of water and the water flows out of the
evaporator 18. This water shedding process is improved via the use
of the hydrophilic coating which inhibits adhesion of water to the
fins.
[0078] The shell 24 has a bulkhead 14 that defines a compartment 92
that houses the condenser 26 and the evaporator 18, as shown in
FIG. 4E. The evaporator 18 is removed to the tent 82 by the miners
upon deployment.
[0079] Inside the XP enclosure 22 is a battery charger 86 that is
used to charge the batteries 21 during maintenance. The battery
charger 86 has an electrical interface that connects to the
electrical power supply present in the mine to receive electricity
from the mine's power supply to recharge the batteries 21.
[0080] The battery charger 86 is connected to the batteries 21 by
way of a bank of fuses 88 and a master breaker. The batteries 21
are formed into pods 90, with four batteries 21 to a pod 90. As
shown in FIGS. 14 and 15. Each battery 21 produces 6 volts. The
four batteries 21 in a pod 90 are connected in series so that a pod
90 produces 24 volts. Each pod 90 is connected in parallel to the
bank of fuses 88, so that if one pod 90 becomes damaged it will not
affect or stop the power output from the other pods 90. Each pod 90
is found in a compartment 92 defined by metal walls, to isolate and
protect each pod 90 from the other and also external forces.
[0081] The battery charger 86 is connected to the master breaker
and through the bank of fuses and the cables extending from the
bank of fuses 88 to each pod 90. When the maintenance mode is
activated, electricity flows from the mine electrical system,
through the charger, master breaker and bank of fuses 88 to the
cables and ultimately to each battery 21 in each pod 90 to charge
each battery 21. A failed fuse is indicated by an LED readout on
the status panel 104, as shown in FIG. 19. FIG. 26 is a graph
showing battery test results.
[0082] The air pumps 58, 60 and the compressor 38, shown in FIG.
4E, receive electricity from the batteries 21 through wiring from
batteries 21 to the master breaker and wiring from the master
breaker to the air pumps 58, 60 and the compressor 38 for their
respective operation. All breakers have automatic resetting
capability so that at any time during operation a breaker is
activated, it will be automatically reset so that electricity can
continue flowing through it without a miner having to leave the
chamber to reset it. In the enclosure 22, there is also a relay
110, a selector switch 112 for mechanical operation, air manifolds
114, a system charger 116, refrigerant connections 118, airline
connections 120, a nitrogen pressure sensor 122 and a thermal
breaker 124.
[0083] Extending from each fuse of the bank of fuses 88 is an MSHA
approved cable that connects to each battery 21 in a pod 90. This
electrical cable electrically connects to specially designed
terminals that extend from each battery 21. See FIGS. 3, 14 and 15.
The terminals 32 are burned onto the battery 21 plates 35 so the
connection of the terminal 32 to the battery 21 plate is completely
shielded from the atmosphere to eliminate the risk of explosion
from the terminal 32 connection. The terminal 32 that extends from
the battery 21 is soldered to the MSHA cable that connects to the
fuse at the XP enclosure 22. The terminal 32 that extends from the
battery 21 plate is also an MSHA approved cable. The connection of
the terminal 32 cable and the cable from the XP enclosure 22 is
made with heat shrink tubing 96 that is soldered to the connection
to protect the connection from the atmosphere and thus corrosion
over time, which again could create a risk of spark or
explosion.
[0084] In regard to the charging and battery system 20, since this
is a battery 21 operated system, this system requires a charging
system. This is accomplished by the connection of 120 VAC mine
power as required (estimated to be on a 3-month interval) to
replenish the battery 21 loss due to system monitoring and natural
battery 21 discharge rates. Although this system uses AGM gel cell
batteries 21 which greatly reduce the incidence of hydrogen off
gassing during the charging cycle, the system is monitored by a
(5-year rated life) hydrogen sensor 98 that disables the system in
the event that hydrogen is sensed. See FIG. 16. The 6 volt
batteries 21 are assembled in pods of 4 and then fuse protected to
prevent a single battery 21 malfunction from disabling the entire
system.
[0085] In regard to the auto resetting system, the system is
equipped with thermal auto-reset breakers in order to provide a
high certainty of operation in a life-dependent environment.
[0086] In regard to the monitoring system, in addition to Hydrogen
monitoring, this system monitors battery 21 charge level and
functionality as well as charging cycles (date and duration of
charge cycle), nitrogen pressure with a nitrogen pressure sensor
94, as well as operational faults. Additionally, this data is
recorded by a data logger that may be retrieved via USB port at
service intervals to system service system or mine central data
system.
[0087] In regard to the operational modes, the system has 3 modes
of operation, Standby-ready for operation, Service-for charging and
data collection and Run-providing cooling for refuge alternative.
See FIGS. 1B-1D.
[0088] In regard to the remote control 102, see FIG. 18, the air
conditioning system 10 is equipped with a fiber optic remote
control 102 remote for operation of the air conditioner system from
the Refuge Shelter 12. The fiber optic remote control 102 is made
by Fiber Switch Technologies, model # SX-921, and is sold by them.
On this air conditioning system 10, the miners can start/stop the
air conditioning system 10, view system faults, monitor battery 21
bank charge remaining as well as a high level reset to provide
maximum opportunity to correct potential faults with status panel
104.
[0089] The refrigerant mass flow rate will fluctuate between 60 and
160 lbs./hr. This fluctuation is due to the compressor's ability to
vary its speed based on the system's heat load. The air to turn the
fan 70 is a fixed value, regardless of the number of occupants in
the Refuge Shelter 12. The air pumps that drive the fan 70 deliver
a combined total of 80 to 110 liters per minute of air, depending
on atmospheric conditions. This is a closed loop system, and none
of this air is intermixed with the refuge air; it is an isolated
system and non-adjustable. The condenser 26 is a fixed size, and
does not vary based on the number of occupants in the refuge. The
evaporator 18 fan 70 will have a speed range of 1200-1800 rpm. The
condenser 26 size can vary +/-2'' in each direction. The intake of
the condenser 26 should be at least 3'' from the ground, which is
guaranteed by where it is mounted to the door 28. The condenser 26
is bolted to the door 28 that opens.
[0090] Maintenance Schedule and Protocol
TABLE-US-00001 Daily Visual inspection of the status panel 104
Battery Charge Condition Nitrogen Pressure Freon Level Check
Methane Level Quarterly Charge & Collect Data Turn switch to
maintenance position Visual inspection of status lights Check H2
Connect laptop/tablet via fiber optic cable Charge system, 6-8 Hr.
typ. Charge time Record & download system information Return
switch to standby mode Annually Complete System Functionality Test
Activate A/C system Confirm operation of the A/C system Replenish
Freon levels as necessary Restore unit to standby mode Battery
Quantities Low Flow Coil Design Power Consumption (Amps)
Refrigerant Compressor 35.5 Air Compressor 4 Sensors 0.6 Refuge
User Interface 0.6 Total 40.7 Batteries 40
[0091] Selector Switch Modes
TABLE-US-00002 SELECTOR SWITCH SW221 MODES Maintenance Standby
(Always Engaged) Cool Item Action Item Action Item Action MS226
Methane When tripped CB222 Main Trips at 50A, MS226 Methane When
tripped Level Switch interlocks out Battery Auto Cools and Level
Switch interlocks out Cool High Maintenance Resetting Resets.
Status High control relay Breaker 50A Indicator Panel CR236 solid
red indicator light HS200 Hydrogen After (??? Min) PSL224 N2 Status
Indicator CB222 Main Control Panel Switch High Delay if no bottles
pressure Panel flash red Battery Auto Power status alarm allows
switch low indicator light Resetting indication is off interlock
relay to Breaker 50A when breaker is engage isolation tripped
relays Blown Fuse When a Battery Fresh Air Bay "Power On" green
Indicators (12 Bank fuse is Control Panel light if main ea) 10A
Banks 1 blown (FU401 Status Indicators breaker is made thru 12 thru
FU412) a and SW221 is in flashing red Cool indicator light "Cool"
green light will show for when cool switch each individual engaged
bank "Freon Compressor Fault" flashing red light when Compress
Control Board shows fault "Air Pumps Fault" flashing red light when
Air Pumps breaker is tripped "Battery Life %" 100% all lights are
on, 75% 1 red 2 amber 1 green is on, 50% 2 amber I green is on, 25%
1 amber 1 Green is on, 0% 1 red is on MS226 Methane Status
Indicator Air Pumps CB237 Auto Reset Level Switch Panel flash red
AP237 & AP238 10 A Breaker High indicator light LSLL228 Freon
Status Indicator Freon Compressor Bottle Switch Panel flash red
Compressor control board Low Low indicator light LSL227 Freon
Status Indicator Control Panel interlocks CR236 Bottle Switch Panel
flash red Cool Pushbutton Cool main control Low indicator light
PBFCB1 relay HQBQ U30 Monitors N2 PSL236 Trickle Interlocks CR236
Data Logger Bottles Switch Pressure switch Cool main control Low,
Methane low relay Level High, Freon Bottle level switch low, Freon
Bottle level switch low low & Battery Voltage
[0092] Testing Schedule/Configuration
TABLE-US-00003 Test No. Test Sequence Config. Evaporator Evap Flow
Condenser 1a Proof Test - Capacity Test SRC # XYZ, forced air 400
CFM, Electric fan SRC # XYZ, forced air 1b Proof Test - Capacity
Test SRC # XYZ, forced air 400 CFM, Electric fan SRC # XYZ, passive
2 Proof Test - Latent Heat Test SRC # XYZ, forced air 400 CFM,
Electric fan SRC # XYZ, forced air 3a New Coils Test NEW SRC LF F/A
150 CFM, Air Motors SRC # XYZ, forced air 3b New Coils Test NEW SRC
LF F/A 150 CFM, Air Motors NEW SRC Passive 4 Full Scale/96 HR.
Actual TBD TBD TBD 5 Full Scale - Tent Test Actual TBD TBD TBD
[0093] Testing Schedule/Configuration (Continued)
TABLE-US-00004 Condenser Flow Evap/Condenser - Envir. Hr. Batts XP
Box Start Date Goal of Test 600 CFM, Electric Fan Insul, Board/Mock
Mine 24 16 none January 2012 Does it work? Baseline capacity.
Natural Insul, Board/Mock Mine 24 16 none January 2012 Gather
passive cond data for SRC. 600 CFM, Electric Fan Insul, Board/Mock
Mine 24 16 none February 2012 Evaluate water shedding of coil. 600
CFM, Electric Fan Insul, Board/Mock Mine 24 16 none February 2012
Evaulate LF evaporator design. Natural Insul, Board/Mock Mine 24 16
none February 2012 Evaluate LF Evap/Passive Cond combo TBD Insul,
Board/Mock Mine 96 48 XP March 2012 TBD Tent/Mock Mine 96 48 XP
March 2012
[0094] Although the invention has been described in detail in the
foregoing embodiments for the purpose of illustration, it is to be
understood that such detail is solely for that purpose and that
variations can be made therein by those skilled in the art without
departing from the spirit and scope of the invention except as it
may be described by the following claims.
* * * * *