U.S. patent application number 16/089431 was filed with the patent office on 2020-09-24 for a compact heat recovery ventilation system.
The applicant listed for this patent is INDUSTRIAL DESIGN LABORATORIES INC., Loftsson JOHANNES, Edward LOPATINSKY, Daniel SCHAEFER. Invention is credited to Loftsson JOHANNES, Edward LOPATINSKY, Daniel SCHAEFER.
Application Number | 20200300498 16/089431 |
Document ID | / |
Family ID | 1000004916268 |
Filed Date | 2020-09-24 |
View All Diagrams
United States Patent
Application |
20200300498 |
Kind Code |
A1 |
LOPATINSKY; Edward ; et
al. |
September 24, 2020 |
A COMPACT HEAT RECOVERY VENTILATION SYSTEM
Abstract
A countercurrent heat recovery ventilation system includes an
air module assembly and heat exchanger assembly. Air module
assembly made from front and back panels connected by two side
panels, base plate fixed with the side panels and placed parallel
between side panels and a double side radial impeller with a shaft,
an electric drive form two hydraulically isolated flow canals with
inlet and outlet openings. The heat exchanger assembly comprises a
heat-exchanger that could be done as changeable flow side
heat-exchanger made as folded corrugated fins or plates, thus each
of the both flow passages split in separate flow channels. Every
other channel is sealed to flow from flow same direction forcing
the flow to be in opposite direction in all adjacent cannels. This
forms two hydraulically isolated flow passages with intake and
outtake openings connected respectively with outlet and inlet
openings of the air blower assembly.
Inventors: |
LOPATINSKY; Edward; (San
Diego, CA) ; SCHAEFER; Daniel; (Kanarraville, UT)
; JOHANNES; Loftsson; (Reykjavik, IS) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
LOPATINSKY; Edward
SCHAEFER; Daniel
JOHANNES; Loftsson
INDUSTRIAL DESIGN LABORATORIES INC. |
San Diego
Kanarraville
Reykjavik
San Diego |
CA
UT
CA |
US
US
IS
US |
|
|
Family ID: |
1000004916268 |
Appl. No.: |
16/089431 |
Filed: |
March 29, 2017 |
PCT Filed: |
March 29, 2017 |
PCT NO: |
PCT/US2017/024865 |
371 Date: |
September 28, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62316325 |
Mar 31, 2016 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F04D 25/08 20130101;
F24F 12/006 20130101; F04D 25/06 20130101; F04D 25/16 20130101 |
International
Class: |
F24F 12/00 20060101
F24F012/00; F04D 25/06 20060101 F04D025/06; F04D 25/08 20060101
F04D025/08; F04D 25/16 20060101 F04D025/16 |
Claims
1. A compact heat recovery ventilation system comprising an air
module assembly with exhaust gas inlet, exhaust gas outlet and
fresh gas inlet, fresh gas outlet, heat exchanger assembly with
exhaust gas intake, exhaust gas outtake and fresh gas intake, fresh
gas outtake, wherein: said air module assembly comprises two side
panels, base plate placed between two radial blowers surrounded by
airflow guides and located on a common axis between each said side
panel and said base plate forming two hydraulically isolated
counter flow canals between said exhaust gas inlet and said exhaust
gas outlet and between said fresh gas outlet and said fresh gas
inlet. said heat exchanger assembly comprising heat exchange
elements surrounded by outside panels with two open ends, each of
said open end divided by a center plate to two separated isolated
flow conduits with said exhaust gas intake, said exhaust gas
outtake and said fresh gas outtake, said fresh gas intake, where
said fresh gas outtake of said conduit hydraulically connected to
said fresh gas inlet of said canal and said exhaust gas intake of
said conduit hydraulically connected to said exhaust gas outlet of
said canal.
2. The compact heat recovery ventilation system per claim 1 wherein
said side panels are parallel to said base plate.
3. The compact heat recovery ventilation system according to claim
1 wherein said base plate of the air module assembly made from two
plates divided in plane perpendicular to the thickness of said base
plate.
4. The compact heat recovery ventilation system according to claim
1 wherein said base plate is parallel to the said outside panels
and the center plate.
5. The compact heat recovery ventilation system according to claim
1 wherein said side panels are directly connected to said outside
panels to form substantially continuous surfaces and said base
plate is directly connected to said center plate to form a
substantially continuous plate.
6. The compact heat recovery ventilation system according to claim
1 wherein the air module assembly connected to heat exchanger
assembly through a flat transition with two airflow ducts.
7. The compact heat recovery ventilation system according to claim
1 wherein the air module assembly connected to heat exchanger
assembly through a L-shape transition with two airflow ducts.
8. The compact heat recovery ventilation system according to claim
1 wherein said compact heat recovery ventilation system is hidden
within a structure envelope inside a building wall, a window frame
or a ceiling.
9. The compact heat recovery ventilation system according to claim
1 wherein said system includes two said radial blowers each
comprising a radial impeller, said impellers integrated with
electric drive and each said impeller spaced from the respective
side of said base plate, each of said radial impellers located at
one of said canals.
10. The compact heat recovery ventilation system according to claim
9 wherein each of said radial impellers comprises set of radial
blades fixed on a back plate disk placed in a cylindrical cavity of
said base plate.
11. The compact heat recovery ventilation system according to claim
10 wherein each of said back plate made from ferrous metal.
12. The compact heat recovery ventilation system according to claim
10 wherein at least one of the back plates includes set of
permanent magnets and along with second said back plate comprises a
rotor of said electric drive.
13. The compact heat recovery ventilation system according to claim
9 wherein said electric drive comprises a flat stator made as
circumferential arrayed coil windings with magnetic axes
perpendicular to a plane of said flat stator and integrated with
said base plate, while said magnetic elements made as
circumferential arrayed permanent magnets magnetized perpendicular
to the plane of said flat stator, thus magnetic axes said coils
windings and said magnets are substantially parallel.
14. The compact heat recovery ventilation system according to claim
9 wherein a stator of said electric drive made as a stator
comprising circumferential arrayed coils windings with magnetic
axes coincided with a plane of said stator and fixed with said base
plate and when electrically powered, creates alternating
electromagnetic fields which interact with a said permanent magnets
of said rotor thus providing a rotation of said two radial
impellers.
15. The compact heat recovery ventilation system according to claim
13 wherein the flat stator located between two said divided
sections of the said base, thus said cylindrical cavities, said
stator and said back plates of the rotor creating a labyrinth
hydraulically isolating said two canals of said air module
assembly.
16. The compact heat recovery ventilation system according to claim
12 wherein outside diameters of said rotors are larger than
diameters of said blades of the radial impellers.
17. The compact heat recovery ventilation system according to claim
9 wherein at least one of said radial impellers is a cross flow
type.
18. The compact heat recovery ventilation system according to claim
9 wherein both of said radial impellers are the cross flow
type.
19. The compact heat recovery ventilation system according to claim
9 wherein both of said radial impellers rotate in one
direction.
20. The compact heat recovery ventilation system according to claim
17 wherein said crossflow impeller further comprises at least one
guide vane surrounded by said radial blades;
21. The compact heat recovery ventilation system according to claim
1 wherein said heat exchanging elements protruding from both sides
of said center plate up to said outside panels.
22. The compact heat recovery ventilation system according to claim
1 wherein said heat exchanging elements shaped as corrugated fins
made as a plurality of channels divided by said center plate to one
said intake and one said outtake openings at one said open end and
one said outtake and one said intake openings at the other said
open end in a way that every even channel of said corrugated fins
is sealed at said intake openings while every odd channel is sealed
at said outtake openings on said another, thus every other channel
is having opposite flow direction to every neighboring channel.
23. The compact heat recovery ventilation system according to claim
21 wherein said center plate has a flat portion across all said
corrugated fins and a plurality dividers perpendicular to said flat
portion and spaced with a double distance of the distance between
neighboring said corrugated fins thus each said divider would seal
every other said corrugated fin at said intake.
24. The compact heat recovery ventilation system according to claim
22 wherein said center plate has a flat portion across all said
corrugated fins and a plurality dividers perpendicular to said flat
portion and spaced with a double distance of the distance between
neighboring said corrugated fins thus each said divider would seal
every other said corrugated fin at said outtake.
25. The compact heat recovery ventilation system according to claim
1 wherein said heat exchanging elements made from plurality of even
and odd plates forming plurality of said channels and said center
plate that has a flat portion across all said plates from both said
open ends and at one said open end at said intake each pair of said
even and said odd plates bended towards each other and sealed and
at another said open end at said intake each pair of odd and even
said plates bended towards each other and sealed and at one said
open end at said outtake each pair of said odd and said even plates
bended towards each other and sealed and at another said open end
at said outtake each pair of said even and said odd plates bended
towards each other and sealed.
26. The compact heat recovery ventilation system according to claim
24 wherein central portion of said plates at the both said open
ends has a bend perpendicular to the plate creating said center
plate across all said channels thus separates the intakes and
outtakes and any said channel is having opposite flow direction to
every next said channel.
27. The compact heat recovery ventilation system according to claim
2, wherein the common axis of the radial blowers is perpendicular
to the side panels.
28. The compact heat recovery ventilation system according to claim
1 wherein at least one of said radial blowers is a cross flow
type.
29. The compact heat recovery ventilation system according to claim
1 wherein both of said radial blowers are the cross flow type.
30. The compact heat recovery ventilation system according to claim
1 wherein both of said radial blowers rotate in one direction.
Description
[0001] The present application claims the benefit of priority of
U.S. Provisional Patent Application No. 62/316,325, filed Mar. 31,
2016 the entire context of which is incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to heat ventilation
and air conditioning (HVAC) systems for moving air, and/or
regulating the temperature, humidity, chemistry and quality of
indoor air. More particularly, the present invention relates to air
processing devices such as ventilators, including heat ventilators,
coolers, air conditioners humidifiers and air purifiers. The
present invention is particularly, but not exclusively, useful for
systems that are mounted inside a wall or ceiling and constitute a
part of room decor; therefore, thickness of the system is a
critical factor. Another critical factor is the countercurrent air
flow (air flowing in opposite directions) that provides the highest
energy recovery efficiency or chemical recovery efficiency. There
is also an important field of application related to the indoor
automotive air ventilation/conditioning systems.
BACKGROUND OF THE INVENTION
[0003] The countercurrent principle is a vital factor in many
ventilation processes. Heating or cooling energy in the exhaust air
can be preserved by recovering it and directing it into the
replacement air through a heat exchanger. Low indoor humidity
levels can also be better maintained in hot and humid environments
by extracting the humidity out of the supply air into the exhaust
air through various countercurrent processes (like desiccant wheel,
water permeable membrane etc.). Same method can be used to help
maintain sufficient high indoor humidity level by extracting much
of the humidity from the exhaust air into the supply air. Some
industrial processes can also benefit from using an extraction
method based on a countercurrent (or cross-current) principle, in
order to minimize pollution or waste, or to make the process more
efficient.
[0004] In addition to these countercurrent processes, good
ventilation systems can also have various other air processing
units, such as filters including activated carbon, humidifier,
dehumidifier, heater, cooler and others, which may improve the
quality of air, while a long duct system may be necessary to
efficiently extract or supply the air in the right locations. All
these processes and systems (countercurrent, cross-current or
in-line) restrict the airflow and contribute to the pressure drop
of the ventilation system. Ambient pressure fluctuations due to
weather or movement of an enclosure is another source of the
pressure load that requires additional power consumption for
ventilation system.
[0005] However, higher power often results in higher sound level,
which is one of the reasons why more powerful systems are
centralized with long bulky ducts and noisy blowers that need to be
closed off in a sound insulated enclosure.
[0006] This brings up one of the major problems for modern
ventilation systems. The powerful ventilation systems are often too
bulky, and the small ones are often not powerful enough. Other
disadvantages of the smaller systems of lower functionality are
that most designs are difficult to conceal, the small size results
in higher motor and blower inefficiency and, as they are closer to
the user, their noise level can still be a nuisance.
[0007] This dilemma causes a problem, specifically in projects,
where there is only limited space available for the ventilation
system, for instance, when older apartments or buildings are being
renovated. In these very common cases, there are often simply no
good solutions possible.
[0008] Most of the current Heat Recovery Systems have traditional
axial fans, which are often used as air moving devices, have
certain limitations because they are not suited to create high
static pressure at given airflow when various air processing units
are added (heat exchanger, filter etc.) and when affected by
ambient pressure fluctuations (e.g., wind loads, vacuum pressure
inside the building envelope). Such designs are described in the
International Patent Application WO 2005/040686 "Window Type Air
Conditioner" and Patent WO2012155913 "Ventilation system with a
rotatable air flow generator and one or more moveable registers and
method for obtaining ventilation through the ventilation
system."
[0009] There are also numerous designs of air processing devices
for HVAC systems that include radial type blowers as air moving
devices, for example, US Patent Application 2005/0257687. Radial
blowers for indoor air processing devices create sufficient static
pressure at a given airflow, but have relatively small diameter of
the impeller. It is well known that for such diameters, the total
blower efficiency decreases dramatically. When a flat centrifugal
blower is mounted flat on the surface in such way that it fits the
structural envelope, the whole design is limited by the suction
being in the center on the flat side and, therefore, perpendicular
to the structural envelope. This leaves little room for any noise
mitigation, like a silencer, unless by compromising the flat
design.
[0010] Crossflow blowers are used in air processing devices more
often due to their affordable mounting performance and a well-known
ability to achieve relatively high efficiency that does not depend
upon diameter size. Moreover, the crossflow blower creates much
more static pressure at the same airflow, unlike the centrifugal
blower, when other conditions are equal. There are many such
designs, for example, International Patent Application WO
2004/085929 "Indoor Unit for Air Conditioner" and Japanese Patent
No. JP2000297945 "An Air Conditioner". According to these designs,
air processing devices comprise a base with a flat surface for wall
mounting and the axis of the crossflow blower is parallel in
respect to that surface. However electric motors for typical
crossflow blowers are located adjacent to the impellers, because if
a conventional electric motor is placed inside the impeller, it
greatly affects the internal aerodynamic structure of the crossflow
blower, thus dramatically decreasing performance
characteristics.
[0011] In some cases it may be beneficial to have two blowers
rotate on the same axis. Having a single motor rotate two blowers
increases the ventilation efficiency benefits, as larger motors are
normally more efficient. An example of one such solution is
described in the US patent application 2013/0101449(A1) "Double
inlet centrifugal blower with peripheral motor", where a peripheral
motor is used to run two concurrent blowers on a single axis.
[0012] Similar solution is also described in a Japanese patent
application 60-75635 "Heat exchanging type fan," consisting of a
casing and two centrifugal fans mounted on the same shaft inside
the casing, but oriented in opposite directions in regard to each
other, creating concurrent flow through a heat exchanger. Two
co-current channels for heat carriers of different temperatures are
formed in the casing, separated by a partition separating both
fans. The heat exchange element comprises radial fins mounted on
both surfaces of the partition beyond the edges of the impellers of
the fans.
[0013] When the fans rotate, the heat carriers enter the
inter-blade space of the fans via the suction inlets and further
on, passing over both sides of the radial fins of the heat exchange
element, are removed from the casing via the respective blower
outlets. Heat exchange takes place through the radial fins and the
partition itself, but as the flow is co-current, the efficiency is
limited. Again a large radial size, inlet perpendicular to the
plane and co-current flow should be listed among the disadvantages
of such arrangement. A heat exchanger solution for co-current
airflow in two channels is described in U.S. Pat. No. 7,837,127 B2
"Ventilation system." This system overcomes the disadvantages of
the co-current airflow by using a very thin "thin wire" heat
exchanger, which effectively creates a countercurrent heat
exchanger between the channels. The countercurrent fix of the
otherwise co-current system has some disadvantages that may limit
its use. The heat exchanger relies on using copper wire, resulting
in higher cost and low pressure drop over the heat exchanger may
cause higher sensitivity to pressure fluctuations.
[0014] Modern air processing devices have become a part of indoor
interior as a wall-mounted system, creating a requirement for thin
box-shaped designs, within the structural envelope. However, all
known designs do not provide a thin air processing device with the
crossflow blower for such wall-mounted air movement systems. The
thickness of known devices with the crossflow blower axis parallel
to the mounting surface is defined by the impeller diameter. Such
solutions are thicker than desired and they do not meet the market
requirements.
[0015] There is a main problem for all known air processing-heat
exchanger devices where they cannot resolve the contradiction
between the high performance that requires a relatively large
impeller diameter on one hand and a small thickness of the whole
device on the other hand.
[0016] Therefore, it is generally desirable to provide a thin,
box-shaped air processing device for indoor HVAC systems with thin
size relatively large diameter efficient blower unit that produces
countercurrent air flow that overcomes such problems in a
mechanically feasible manner.
[0017] Heat-exchanger is one of the most important part of the
countercurrent heat recovery ventilation system.
There are at least a few options that could be used for this
proposed application such as:
[0018] traditional one made as a central plate with protruded fins
or pins from both sides of the center plate. As the center plate
forms separation between the two countercurrent air streams along
the length of the heat exchanger, the flow is restricted to exit on
the other end of the heat exchanger on the same side as it
entered.
[0019] changeable air flow sides could be made in the following
ways: designed as folded fins with a center plate divider, or as
plate heat exchanger based on the same principals as changing air
flow sides. The center plate dividers are only located at the open
ends of the heat exchanger but not inside it. This gives additional
flexibility in design as the air is free to move between one side
of the outside panel at the intake of heat exchanger, to the
opposite side of outside panel at the outtake of heat exchanger. In
the same time the airstream is separated to plurality of thin
airstreams moving in a way that any other thin stream flows in
opposite direction.
[0020] The last design of such heat exchanger is described in
patent DE4301296 "Plate heat exchange on countercurrent principle"
and incorporated here by reference.
[0021] Space for the air filter unit in most current systems are
included as part of the HVAC treatment box.
[0022] There are some building solutions which are having
ventilation ducts integrated into a wall, a slab or a raised floor.
Such solutions are described in patents US 2008 0142610(A1)
"Integrated structural slab and access floor HVAC system for
buildings ",KR Patent 2010 0002817 (A)"Slab structure" and KR
patent 2015 101576615 (B1) "Hollow core slab integrated ventilation
deck plate". There is, however, too little space for air processing
units, and blower inside these slabs.
[0023] Efficient motor is very important part for any heat recovery
system as the part that providing energy saving. Several
improvements for better motor efficiency level have been done
according to US Patent 2004 245866 (A1) "Integrated cooler for
electronic devices," which describes a flat cooling unit consisting
of crossflow blower connected to heatsink removing heat from a
co-current flow around heat pipes. US Patent 2005 121996A1
"Electric dive for radial impeller" describes a flat peripheral
motor with coils printed on a PCB board and magnetic means fixed
with the radial impeller and even integrated in the blades. This
compact design has high efficiency which is increased further by
leaving space in center of the radial blower allowing higher
airflow. US patent 2006 0006745A1. "Integrated blower for cooling
device" describes a peripheral motor for a radial blower with
stator and rotor in the same plane. This arrangement produces lower
motor vibration, which results in lower motor noise, higher
efficiency and ensures higher airflow. US patent 2006 238064A1
"Flat radially integrated electric drive and method of the
manufacturing the same", describes stator of the motor printed in a
PCB board where the motor and the rotor are on the same plane. US
2006 056153 A1 "Multi-heatsink integrated cooling device,"
describes flat crossflow cooler connected to two heat sinks. US
Patent 2008 101966A1 "High efficient compact radial blower"
describes an integrated blower, motor and heat sink, which uses
printed coils, and locates the heat sink inside the blower. US
Patent 2007 166177(A1) "Thin air processing device for heat
ventilation air conditioning system", describes an efficient design
for a single flat cross flow blower and the benefits of connecting
it to an air processing unit like purifier, humidifier or
temperature regulating means. US Patent 2008 238218(A1) describes
an improved method of arranging coils in motor partially printed on
a PCB board. This arrangement increases the motor power, and
efficiency.
[0024] All these prior art designs still have some disadvantages
that limited abilities to create flat compact heat recovery system
capable to be soundless, wall-mounted or even fit inside of the
wall or ceiling. It would be highly desirable to use the advantages
of the known prior art along with the novelty elements that would
be described further per our patent application.
SUMMARY OF THE INVENTION
[0025] The present invention is an approach to resolve in
particular situations where only limited space is available for
ventilation system, by inventing a ventilation system that can
easily be integrated into the structural envelope of an enclosure
(building, car, boat, plane or similar). Such configuration is
achieved herein by a system, based on the countercurrent principle,
with flat countercurrent heat exchanger and flat blowers powerful
enough to perform and the system thin enough to fit inside the wall
or ceiling.
[0026] Using a flat countercurrent ventilation system made up of
matching flat air treatment modules which all have identical
thickness and width and for different countercurrent air treatment
processes, provides novelty of the design.
[0027] An additional benefit of the compact flat system of the
invention, is that the system's length does not have to be
restricted. Any air handling unit which has the same thickness and
width can be added to the system without compromising aesthetics or
style of the system. This gives the system additional functional
flexibility (modularity), as each of the air treatment modules can
be chosen independently so that it can meet its functional
requirements, thus allowing for additional flexibility in
design.
[0028] According to the present invention, the whole heat recovery
system is made from two major components, namely a air module
assembly and heat exchanger assembly.
[0029] The air module assembly comprises two radial blowers
surrounded by airflow guides, placed on the common axis using
peripheral motor. Housing made from two side panels and base plate
between these side panels. These blowers along with airflow guides,
side panels and base plate form two hydraulically isolated counter
flow canals with inlet and outlet openings for each of the
canal.
[0030] Heat exchanger assembly comprises a box with heat exchange
elements surrounded by outside panels. The box, further compromises
an intake and outtake openings and a center plate dividing the
whole heat exchanger assembly in two hydraulically isolated flow
conduits with intake and outtake openings. Side panels of the air
module assembly are fixed with outside panels of the heat
exchanger. Base plate of the air module assembly is fixed with
center plate of the heat exchanger assembly. Therefore, such
arrangement allows hydraulically connecting canals of the air
module assembly to flow conduits of heat exchanger assembly
respectively.
[0031] The air module assembly comprises a base plate fixed with
the side panels thru airflow guides and placed parallel between the
side panels.
[0032] Two radial blowers are spaced between side panels from both
sides of the base plate, while the other part of the base is fixed
to the center plate of the heat exchange assembly. Two radial
blowers further comprise two radial impellers spaced from both
sides of the base plate, thus each of the radial impellers is
located at one of flow passages. Each of the radial impellers
comprises a back plate disk with radial blades that are spaced
apart.
[0033] Heat exchanging elements protruding from both sides of the
base plate thus spaced inside of each flow passages are forming an
exhaust and fresh heat-exchanging sides of the integrated heat
exchanger.
[0034] The heat-exchanger could also done as changing flow side
heat-exchanger made as folded fins or plates, thus each of the both
flow passages split in many separate flow channels. Every other
channel forcing the flow in the opposite direction.
[0035] The electric drive preferably comprises a flat stator fixed
attached to the base plate, and a rotor with magnetic elements
integrated with at least one of the back plate disk, thus the
double side radial impeller serves as the rotor of the motor. The
stator size (diameter) is larger than the radial blower diameter,
when electrically powered, creates alternating electromagnetic
fields that interact with a magnetic field created by the magnetic
elements, thus providing a rotation of the double side radial
impeller, causing the exhaust gas flow through the outtake side of
the heat exchanger, while fresh gas flows through the intake side
of the heat exchanger.
[0036] The base plate of the air module assembly further comprises
volute casings for each of the radial impeller, that formed by flow
guides protruding from both sides of the base plate, one of the two
flow guides serves as a tongue of the volute casing, while the
other flow guide serves as a spiral part.
[0037] According to the first embodiment, one of the inlet opening
(exhaust gas out) is located at the side panel, both radial
impellers rotate in one direction and one of the radial impellers
operates as a centrifugal blower, while the other radial impeller
operates as a crossflow blower. At the same time, the flow guides
of the centrifugal blower serve as the volute casings directing the
airflow for one part of the flow canal. The flow guides on other of
base plate create the second flow canal made by crossflow
blower.
[0038] The Heat Exchanger assembly includes heat exchanging
elements located in the line of the intake and the outtake openings
in a consecutive way for the flow conduits, thus providing
counter-flow heat exchange process. In this case, the electric
drive can be made as a conventional electric motor spaced inside of
the radial impeller of the centrifugal blower.
[0039] According to the second embodiment of the present invention,
the radial impellers rotate in one direction and operate as
crossflow blowers, two flow guides are shifted in view
perpendicular to the shaft in angular direction, therefore the
fresh gas flows through the intake openings, the heat exchanging
elements, inlet, the crossflow impeller and the outlet openings in
a consecutive way, while other air flows through the inlet
openings, the radial impeller, intake of the heat exchanging
elements, outtake in a consecutive way form another flow passage,
thus providing countercurrent flow heat exchange process. In this
case the electric drive can be made as a peripheral thin motor
placed between crossflow impellers.
[0040] The heat exchanger assembly can further comprise the heat
exchanging elements, thus forming two elongated flow passages
serving as the exhaust and fresh sides of the integrated heat
exchanger.
[0041] The heat exchanging elements for all embodiments can be made
in a few ways:
[0042] In the most general configuration, when heat exchanging
elements protruding from both sides of the center plate thus spaced
inside of each flow passages form an exhaust and fresh
heat-exchanging sides of the integrated heat exchanger.
[0043] The heat-exchanger could also be built as changing flow side
heat-exchanger made as folded fins or plates, thus both flow
passages split in plurality of flow channels. Every other channel
would be forcing the flow in opposite direction.
[0044] The last approach is the most beneficial for our proposed
application since the air passages are changing sides inside of the
system, thus when the system is installed in the wall or ceiling,
the air from the inside of the enclosure travels towards outside of
the enclosure naturally, with no special ducts.
[0045] A preferred heat-exchanger for this design is per patent DE
4301296 A1 with some improvements described further.
[0046] Several design options for the electric drive can be used
here in accordance with the invention. According to one design
option the flat stator comprises circumferential arrayed coil
windings with magnetic axes coincided with a plane of the flat
stator and integrated with the base plate, while the magnetic
elements made as circumferential arrayed permanent magnets are
placed and magnetized along the plane of the flat stator, thus
magnetic axes of the coil windings and the permanent magnets are
located at one plane substantially.
[0047] For all embodiments, when the radial impellers are
operating, as crossflow blowers including guides integrated with
the side panels correspondingly, the exhaust air flows through the
intake opening, the heat exchange elements, the radial impeller,
and the outlet openings in a consecutive way for one airflow
passage while the other airflow passage of the fresh air flows
through inlet opening, radial impeller, heat exchange elements and
outtake opening.
[0048] The foregoing and other objectives, features and advantages
of the invention will be more readily understood upon consideration
of the following detailed description of the invention, in
conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] FIG. 1 is a perspective view showing the first embodiment of
the compact heat recovery ventilation system for the present
invention containing one centrifugal and one crossflow blower.
(ducts and filters are not shown)
[0050] FIG. 2 is a perspective view showing the second embodiment
of the compact heat recovery ventilation system for the present
invention containing two crossflow blowers. (ducts and filters are
not shown).
[0051] FIG. 3 is an exposed view of one of the crossflow blowers
from FIG. 2 that shows the integrated crossflow blower including
motor elements.
[0052] FIG. 4 is perspective view showing the second embodiment of
the current invention including ducts.
[0053] FIGS. 5-7 are schematic views showing options for mounting
inside the wall or ceiling for the compact heat recovery
ventilation system using changing side heat exchanger for the
present invention.
[0054] FIGS. 8-10 are schematic views showing options for mounting
inside the wall or ceiling for the heat recovery system using
traditional heat exchanger for the present invention
[0055] FIGS. 11-12 are schematic views showing options for mounting
on the wall or ceiling for the compact heat recovery ventilation
system using changing side heat exchanger for the present
invention.
[0056] FIGS. 13-14 are schematic views showing options for mounting
on the wall or ceiling for the compact heat recovery ventilation
system using traditional heat exchanger for the present
invention.
[0057] FIG. 15 Flat schematic view showing all connected in length
components including blower, heat exchanger, filter, silencers with
the exhaust gas duct.
[0058] FIG. 16 Flat schematic view showing all connected in length
components including blower, heat exchanger, filter, silencers with
the fresh gas duct.
[0059] FIG. 17 is a cross section of the two blowers including
integrated motor placed inside the housing.
[0060] FIG. 18a is showing a traditional heat-exchanger view from
the intake and outtake; FIG. 18b showing a traditional
heat-exchanger cross-sectioned along the flow conduit.
[0061] FIG. 19a is showing a changing flow sides corrugated fins
heat-exchanger front view from one open end;
[0062] FIG. 19b the same heat-exchanger back view from the other
open end.
[0063] FIG. 19c is showing cross-sectioned along one of the odd
changing sides flow conduit.
[0064] FIG. 19d is showing cross-sectioned along one of the even
changing sides flow conduit.
[0065] FIG. 20a is showing a changing flow sides plate fins
heat-exchanger 3d section view from the open end (top outside panel
is not shown).
[0066] FIG. 20b is showing cross-sectioned along one of the odd
changing sides flow conduit.
[0067] FIG. 20c is showing cross-sectioned along one of the even
changing sides flow conduit.
[0068] FIG. 21 is a perspective view showing the second embodiment
of the current invention with L-shaped transition duct between heat
exchanger and blowers.
[0069] FIG. 22 is a perspective view showing the second embodiment
of the current invention with L-shaped heat exchanger.
[0070] FIG. 23 is a perspective view showing the second embodiment
of the current invention with 2 transition ducts between the heat
exchanger assembly and air module assembly.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0071] Preferred embodiment of the present invention will be
described in detail below with reference to the accompanying
drawings.
[0072] A compact heat recovery system 1 (FIGS. 1-23) comprises air
module assembly 2 and heat exchanger assembly 3. Air module
assembly 2 includes base plate 4, two radial blowers 5 and 6
airflow guides 7, two side panels 8 and 9. The base plate 4 located
between radial blower 5 and 6, divides the airflow in two
hydraulically isolated canals, exhaust gas canal 12 and fresh gas
canal 13 with exhaust gas inlet 14, fresh gas inlet 15 and exhaust
gas outlet 16, fresh gas outlet 17.
[0073] The heat exchanger assembly 3 comprises of heat exchanging
elements 20, center plate 21 fixed with outside panels 22 and 23
and withe with heat exchanger sides 18 and 19. The center plate 21
divides openings of the ends 24, 25 of the heat exchanger assembly
3 for two hydraulically isolated flow conduits 28 and 29 with
exhaust gas intake 31, fresh gas intake 32 and exhaust gas outtake
34, fresh gas 36 outtake located at the ends 24, 25. The base plate
4, side panels 8, 9 of the air module assembly 2 connected
respectively to the center plate 21, outside panels 22, 23 of the
heat exchanger assembly 3.
[0074] The FIG. 1 shows the option of two blowers 5 and 6, one of
them is a centrifugal blower 41 and the other is a cross flow
blower 42. Both blowers 41 and 42 placed on the common shaft 44 and
integrated with electric drive 45.
[0075] The FIG. 2 shows the option of two radial blowers 5 and 6,
both of them made as crossflow blowers 49 and 50.
[0076] According to the (FIGS. 2-4) of the present invention both
crossflow impellers 46 and 47 placed on the common shaft 44 and
integrated with electric drive 45, rotate in one direction and
operate as crossflow blowers 49, 50. Two airflow guides 51, 52 are
outside the cross flow impellers 46, 47 and a guide vain 56 is
located inside of each cross flow impeller 46, 47, therefore,
exhaust gas flows through exhaust gas inlet duct 54A, exhaust gas
inlet 53, cross flow blower 49, in exhaust gas canal 12, exhaust
gas outlet 53A, exhaust gas intake 31 through heat exchanging
elements 20 and exhaust gas outtake 34 of heat exchanger assembly 3
and exhaust gas outtake duct 54, while fresh gas flows through the
fresh gas intake duct 55, fresh gas intake 32 through heat
exchanging elements 20, fresh gas outtake 36 of the heat exchanger
assembly 3, fresh gas inlet 15, cross flow blower 50 in fresh gas
canal 13, and fresh gas outlet 17, fresh gas outlet duct 55A of air
module assembly 2, thus providing countercurrent heat exchange
process.
[0077] According to FIG. 17, the double radial impeller 57
comprises two radial impellers 46 and 47 that are respectively
spaced between each side 58 and 59 of the base plate 4 and side
panels 8 and 9, thus each of the radial impellers 46 and 47 located
in each of the canal 12 and 13. Each of the radial impellers 46 and
47 attached to back plate disk 60 and 61 that are fixed to the hub
69 attached to shaft 44 based on bearings 71, 73 pressed in the
side panels 8 and 9. One of the back plate disk 61 comprises
magnetic elements 62, thus both of the back plate discs 60 and 61
form the rotor 63. Base plate 4 is divided in plane perpendicular
to its thickness in two parts 64, 65 having between them a stator
67 that along with rotor 63 serves as the electric drive 45 of the
air module assembly 2.
[0078] There are at least two design options for the electric drive
45. According to a first design option (FIG. 3), the stator 67
comprises of a circumferential arrayed coil windings 72 with
magnetic axes coincided with a plane of the flat stator 67 and
integrated with the base plate 4, while the magnetic elements 62
made as circumferential arrayed permanent magnets 70 placed and
magnetized along the plane of the flat stator 68, thus magnetic
axes of the coil windings 69 and the permanent magnets 70 located
at one plane substantially. Such electric drive 45 is described in
details in the U.S. Pat. No. 7,173,353 for the same Assignee.
[0079] According to a second design option (FIG. 17), the flat
stator 68 comprises circumferential arrayed coil windings 72 with
magnetic axes perpendicular to a plane of the flat stator 68 and
integrated with the base plate 4, while the magnetic elements made
62 as circumferential arrayed permanent magnets 70 are magnetized
perpendicular to the plane of the flat stator 68, thus magnetic
axes of the coils windings 72 and the permanent magnets 70 of the
rotor 63 are substantially parallel. Peripheral parts 60 and 61 of
the rotor 63 placed inside of cylindrical cavities 91 and 92,
creating a labyrinth 93 hydraulically isolating canals 12 and 13 of
air module assembly 2.
[0080] All electrical coils made as printed overlapping coils on
the PC board in accordance with the U.S. Pat. No. 7,623,013 that is
incorporated in this application by reference.
[0081] FIG. 15 shows the fresh gas passage in a planar section of a
compact heat recovery ventilation system 1, including air module
assembly 2, heat exchanger assembly 3, fresh air filter assembly 86
and silencer assemblies 87. Fresh gas flows through filter assembly
86, silencer assembly 87, heat exchanger assembly 3, transition
duct 88, crossflow blower 50 of air module assembly 2, and through
a silencer assembly 87.
[0082] FIG. 16 shows the exhaust gas passage in a planar section of
a compact heat recovery ventilation system 1, including air module
assembly 2, heat exchanger assembly 3, fresh air filter assembly 86
and silencer assemblies 87. Exhaust gas flows through filter
assembly 86, silencer assembly 87, crossflow blower 49 of air
module assembly 2, transition duct 88, heat exchanger assembly 3,
silencer assembly 87 and exhaust gas outtake duct 54.
[0083] FIG. 18a and FIG. 18b shown one of the options for heat
exchanger assembly 3 with traditional heat exchange elements 20
made as a center plate 21 with protruded fins 76 from both sides of
the center plate 21. As the center plate 21 forms separation
between the two conduits 28, 29 along the length of the heat
exchanger assembly 3. Exhaust gas is restricted to flow through
conduit 28 from end 25 to end 24 along the side of the outside
panel 22 thus exiting on the same outside panel side 22 as entered.
Fresh gas is restricted to flow through conduit 29 from end 24 to
end 25 along the side of the outside panel 23 thus exiting on the
same outside panel side 23 as it entered.
[0084] FIGS. 19(a,b,c,d) show changeable gas flow side heat
exchangers could be made as corrugated fins with a base plate
divider or as plate heat exchanger based on the same principles
FIGS. 20(a,b,c,d). The center plate 21 splits in two end center
plates 74, 75 located respectively at the ends 24, 25 of the heat
exchanger assembly 3 for both configurations.
[0085] Option shown in the FIG. 19 (a,b,c,d) includes the heat
exchanger assembly 3 with heat exchanging elements 20 shaped as
corrugated fins 78 made as a plurality of channels 79 divided by
end center plate 74 and 75 located respectively at the ends 24, 25
of the heat exchanger assembly 3.
[0086] End 25 has exhaust gas intake 31 and fresh gas outtake, 36
while the end 24 has fresh gas intake 32 and exhaust gas outtake
34.
[0087] At the exhaust gas intake 31 at the end 24 every even
channel 81 is sealed and every odd channel 82 is open, while at the
fresh gas outtake 36 at the same end 24 every odd channel 82 is
sealed and every even channel 81 is open.
[0088] For this particular heat exchanger with heat exchanging
elements 20 at exhaust gas flows through the exhaust gas intake 31
next to outside panel 22 at end 24, through open odd channels 82 to
the exhaust gas outtake 34 next to outside panel 23 at end 25, thus
gas is forced to change sides.
[0089] Fresh gas flows through the fresh gas intake 32 next to
outside panel 23 at end 25, through open even channels 81 out to
the fresh gas outtake 36 next to outside panel 22 at end 24, thus
gas is forced to change sides.
[0090] Option shown in the FIGS. 20(a,b,c,d) includes the heat
exchanger assembly 3 with heat exchanging elements 20. The heat
exchanging elements 20 are of plate type, where at both ends 24 and
25 at exhaust gas outtake 34 and exhaust gas intake 31 plurality of
pairs of all odd plates 84 and even plates 83 are bended and sealed
together.
[0091] At both ends 24 and 25 at fresh gas intake 32 and fresh gas
outtake 36 pluralities of pairs of all even plates 83 and odd
plates 84 are bended and sealed together.
[0092] At the end 24 of the heat exchanger assembly 3 the exhaust
gas intake 31 is separated from fresh gas outtake 36 by center
plate 74.
At the end 25 of the heat exchanger assembly 3 the fresh gas intake
32 is separated from exhaust gas outtake 34 by center plate 75.
[0093] For this particular heat exchanger assembly 3 with heat
exchanging elements 20 the exhaust gas flows through the exhaust
gas intake 31 next to outside panel 22 at end 24, through open odd
channels 82 to the exhaust gas outtake 34 next to outside panel 23
at end 25, thus gas is forced to change sides.
[0094] Fresh gas flows through the fresh gas intake 32 next to
outside panel 23 at end 25, through open even channels 81 out to
the fresh gas outtake 36 next to outside panel 22 at end 24, thus
gas is forced to change sides.
[0095] This gives additional flexibility in design as the air is
free to move between opposite sides of the heat exchanger, and the
air can exit on the other end of the heat exchanger on the opposite
side than it entered.
[0096] The principals of such heat exchanger are described in U.S.
Pat. No. DE4,301,296 "Plate heat exchange on countercurrent
principle" and incorporated here by reference.
[0097] The heat exchangers described in FIGS. 19 and 20 are the
most beneficial for our proposed application. The heat transfer
distance is much shorter, and therefore, the heat exchanger
efficiency relies in much lesser degree on heat conductance
coefficient of the heat exchanger material. The heat exchanger can
therefore be made out of plastic material. By using a vapor
permeable material in the heat exchanger folded fins or plate,
humidity can be recovered. Thus, upgrading the heat recovery system
to an energy recovery system.
[0098] The changing or sides of the airflow inside the heat
exchanger, is also beneficial as it can be used to prevent
formation of dead pockets inside the heat exchanger which may
accumulate and condensate dirt, hence, having both outlets on the
bottom side can help reduce any such accumulation inside the heat
exchanger.
[0099] There are several alignments of heat exchangers assembly 3
and air module assembly 2 that are possible in the compact heat
recovery ventilation system 1.
[0100] FIGS. 21, 22 and 23 show three different alignments of the
compact heat recovery ventilation system 1. FIG. 21 shows L-shaped
transition 89 where heat exchanger outside panels 22,23 and center
plate 21 no longer connect directly with the air module assembly 2,
and are no longer parallel with side panels 8,9 or base plate 4 of
the air module assembly 2. FIG. 22 shows a configuration where the
compact heat recovery ventilation system 1 has a bent exchanger
assembly 3. FIG. 23 shows configuration where the compact heat
recovery ventilation assembly 1, has two separate transition ducts
connecting heat exchanger assembly 3 to the air module assembly
2.
[0101] According to FIG. 21 of the present invention the air module
assembly 2 is connected to the heat exchanger assembly 3 with
transition ducts. The exhaust gas flows through the exhaust gas
duct inlet duct 54A, exhaust gas inlet 14, crossflow blower 49 in
the exhaust gas canal 12 of the air module assembly 2, the exhaust
gas outlet 53A, the exhaust transition channel 90 of the L shaped
transition 89, exhaust gas intake 31 through heat exchanging
elements 20 and exhaust gas outtake 34 of heat exchanger assembly
3, while fresh gas flows through the fresh gas intake 32 through
heat exchanging elements 20, fresh gas outtake 36 of the heat
exchanger assembly 3, fresh air transition channel 91 of the
transition 89, fresh gas inlet 15, cross flow blower 50 in fresh
gas canal 13, and fresh gas outlet 17, fresh gas outlet duct 55A of
air module assembly 2, thus providing countercurrent heat exchange
process.
[0102] According to FIG. 22 of the present invention the air module
assembly 2 is connected to the heat exchanger assembly 3 which is
L-shaped. The exhaust gas flows through the exhaust gas inlet duct
54A, exhaust gas inlet 14, crossflow blower 49 in the exhaust gas
canal 12 of the air module assembly 2, the exhaust gas outlet 16,
exhaust gas intake 31 through heat exchanging elements 20 and
exhaust gas outtake 34 of the L shaped heat exchanger assembly 3,
while fresh gas flows through the fresh gas intake 32 through heat
exchanging elements 20, fresh gas outtake 36 of the L-shaped heat
exchanger assembly 3, fresh gas inlet 15, cross flow blower 50 in
fresh gas canal 13, and fresh gas outlet 17, fresh gas outlet duct
55A of air module assembly 2, thus providing countercurrent heat
exchange process.
[0103] According to FIG. 23 of the present invention the air module
assembly 2 is connected to the heat exchanger assembly 3 with
transition duct assembly 94. The exhaust gas flows through the
exhaust gas inlet duct 54A, exhaust gas inlet 14, crossflow blower
49 in the exhaust gas canal 12 of the air module assembly 2, the
exhaust gas outlet 16, exhaust gas transition duct 95, exhaust gas
intake 31 through heat exchanging elements 20 and exhaust gas
outtake 34 of heat exchanger assembly 3, while fresh gas flows
through the fresh gas intake 32 through heat exchanging elements
20, fresh gas outtake 36 of the heat exchanger assembly 3, fresh
gas transition duct 96, fresh gas inlet 15, cross flow blower 50 in
fresh gas canal 13, and fresh gas outlet 17, fresh gas outlet duct
55A of air module assembly 2, thus providing countercurrent heat
exchange process.
[0104] The compact heat recovery ventilation system 1 operates in
the following way. When an electric power is supplied to the flat
stator 68 of the electric drive 45, the alternative electromagnetic
field is created. This electromagnetic field is controlled by the
electronic controllers (not shown on Figs.) and interacts with a
magnetic field created by the magnetic rotor 63. As a result of
this interaction, the magnetized rotor 63 causes the double radial
impeller 57 to rotate. The exhaust gas flows through the exhaust
gas inlet duct 54A, crossflow blower 49 in the exhaust gas canal 12
of the air module assembly 2, the exhaust gas outlet 53A, exhaust
gas intake 31 through heat exchanging elements 20 and exhaust gas
outtake 34 of heat exchanger assembly 3 and exhaust gas outtake
duct 54, while fresh gas flows through the fresh gas intake duct
55, fresh gas intake 32 through heat exchanging elements 20, fresh
gas outtake 36 of the heat exchanger assembly 3, flexible fresh air
transition channel 91 of the transition 89, fresh gas inlet 15,
cross flow blower 50 in fresh gas canal 13, and fresh gas outlet
17, fresh gas outlet duct 55A of air module assembly 2, thus
providing countercurrent heat exchange process.
[0105] According to the present invention, the compact heat
recovery ventilation system 1 due to the mutual arrangement of the
hydraulic schemes of the crossflow blowers 42 with the double side
radial impeller 75 parallel to the base plate 4 of the air module
assembly 2, provides a thin, compact, highly efficient, simple,
reliable and less expensive device that can easily be mounted
inside the wall, ceiling or inside a vehicle.
[0106] These combination of the dual thin blowers with the
integrated single motor between them, mounted with the side
changeable heat exchanger including additional modules such as
filters, silencers, humidifiers, assembled in a flat modular way,
allows to create a flat compact heat recovery system capable of
being soundless, wall-mounted or even be able to fit inside of the
wall or ceiling.
[0107] While the invention has been described with reference to
various embodiments, it should be understood that these embodiments
are only illustrative and that the scope of the invention is not
limited to just those. Many variations, modifications and
improvements of the embodiments described are possible. Variations
and modifications of the embodiments disclosed herein may be made
based on description set forth herein, without departing from the
scope and spirit of the invention as set forth in the following
claims.
In accordance to the above description of proposed invention first
prototype of such system was manufactured, installed in the
standard wall and successfully tested.
* * * * *