Refrigerant based heat exchange system
The present invention comprises an improved refrigerant based heat exchange system useful in air conditioning and refrigeration applications. Improved heat transfer capability is achieved by using a dual heat exchanger with two different heat-transfer mediums, air and water, in one condenser unit and by advancing the water transfer medium ahead of the air transfer medium. Bypass controls are provided for bypassing a selected heat exchange section of the system depending upon existing environmental conditions. The system is optionally housed in a decorative facade which provides an exposed surface adorned with esthetically pleasing artwork.
The present application claims priority from a provisional application Ser. No. 60/654,618, filed Feb. 17, 2005, by Eric Barger, entitled “Heat Exchanger For Evaporative Cooling Refrigeration System.”
BACKGROUND OF THE INVENTION1. Field of the Invention
The present invention relates generally to refrigerant based heat exchange systems employing a compressor, a condenser, an evaporator and associated fluid circuitry used for air conditioning, food storage refrigeration, and similar applications, and to improvements in the condenser sections of such systems.
2. Description of the Prior Art
In a typical commercially available air conditioning or refrigeration unit, a condensable refrigerant is compressed, condensed, cooled and then supplied to a metering device and evaporator for cooling a surrounding environment. The condensers of such refrigeration systems are usually cooled by ambient air or by water supplied from an external source. The following references are intended to be merely illustrative or representative of the general state of the art in air, water and air/water cooled condensing heat exchangers.
U.S. Pat. No. 5,832,739, issued Nov. 10, 1998, to Bacchus, shows an air conditioner operating on a compressor-condenser circuit which utilizes water cooled by air flowing over an evaporative medium through which the water flows to cool a condenser coil located in a continuous serpentine channel in a sump member located at the lower side of the air conditioner unit. This unit is a purely water cooled unit which fails to offer redundancy in the form of an auxiliary water coil in addition to the air coil. At certain times of the year, i.e., under freezing conditions, a water cooled only unit may freeze up or fail to function efficiently. Purely water cooled units are also more likely to fail due to maintenance requirements.
U.S. Pat. No. 4,182,131, issued Jan. 8, 1980, to Marshall et al., shows an air conditioning system in which the Freon passes first to an air coil, and secondly to a water bath. The water which is heated up in the sump region of the device is passed over evaporative media to provide a cooling effect and make heat transfer over the air coil more effective.
U.S. Pat. No. 6,862,894, issued Mar. 8, 2005, to Miles, Sr., describes a piggy-back type water cooled auxiliary condenser device used in a food refrigeration system. The water cooled system provides failure detection and a stop-gap solution for failure of the air cooled coil. The refrigerant in the system is circulated first to the air cooled coil and secondly to the water cooled auxiliary coil if the air cooled coil fails.
U.S. Pat. No. 6,748,759, issued Jun. 15, 2004, to Wu, shows a heat exchanger having vertical cooling fins with a drip-drop type water feeding box for feeding water drops to the top of the cooling fins. The refrigerant is circulated in a path which is acted upon simultaneously by both air and water cooling effects.
U.S. Pat. No. 6,857,285, issued Feb. 22, 2005, to Hebert, shows a system which achieves an increased refrigeration effect in which the liquid refrigerant line coming off of an air condenser of an air conditioner is serially connected to a water subcool and/or pre-cool heat exchanger before being connected to the line leading to the expansion device of an air conditioning, refrigeration or heat pump system.
Although certain of the devices shown in the above discussed patent literature utilize a combination of air cooling and water cooling in an air conditioning system, the present invention provides a number of improvements in the operation and design of such systems, as well as providing superior energy efficiency over state of the art systems.
SUMMARY OF THE INVENTIONThe present invention accordingly has as one object to provide an improved heat exchanger design which improves and facilitates the heat transfer effect achieved within the condenser section of the heat exchanger.
Another object of the invention is to provide a heat exchanger with improved heat transfer between the condenser and refrigerant circulated through the condenser by using a dual heat exchanger with both air and water heat transfer mediums in one condenser unit and advancing the water transfer medium ahead of the air transfer medium.
Another object of the invention is to provide an improved air conditioning system which utilizes a condenser section having both a water cooled sub section and an air cooled sub section to provide, improved operating efficiency, redundancy, and the ability to operate in cold ambient conditions where freezing might otherwise inhibit the use of water cooling.
Another object of the invention is to provide a condenser circuit for an air conditioning system having both water and air cooled subsections, in which the water cooled sub section is always located before the air cooled subsection to provide an initial cooling effect using water, thereby increasing the efficiency of the system.
Another object of the invention is to provide a condenser circuit for an air conditioning system having both water and air cooled subsections which is provided with appropriate by-pass circuitry for optionally by passing a selected one of the cooling subsections.
In one broad aspect, the present invention comprises a refrigerant based heat exchange system including a condensing heat exchanger and an evaporating heat exchanger connected in a refrigerant circuit. A compressor circulates refrigerant between the condensing heat exchanger and the evaporating heat exchanger in the refrigeration circuit. The condensing heat exchanger includes both a water cooled subsection and an air cooled subsection for redundancy. By pass means are provided, as a part of the refrigerant circuit, for alternately directing the flow of refrigerant in the refrigerant circuit through either or both of the water cooled subsection and the air cooled subsection of the condensing heat exchanger.
In one case, the water cooled subsection and the air cooled subsection are located in series in the refrigerant circuit and the water cooled subsection precedes the air cooled subsection.
In another case, the water cooled subsection and the air cooled subsection are arranged in parallel fashion within the refrigerant circuit and wherein a control valve is located in the refrigerant line ahead of each subsection, the valves being operable to direct refrigerant first to the water cooled subsection when both the subsections are being utilized.
Both the water cooled subsection and the air cooled subsection of the condensing heat exchanger include heat exchange surface areas, and wherein air flow from a source of forced air is used to provide a cooling effect over at least the air cooled heat exchange surface area, and wherein the source of forced air is arranged so that the air flow always contacts the heat exchange surface area of the air cooled subsection prior to contacting the heat exchange surface area of the water cooled subsection of the condensing heat exchanger.
In one version of the refrigerant circuit, each of the water cooled subsection and the air cooled subsection of the condensing heat exchanger has a refrigerant line in and a refrigerant line out and a by pass line connecting the two and a check valve located downstream of the respective heat exchanger subsection, and wherein a valve means precedes each subsection for directing flow of refrigerant to the heat exchanger subsection or to the by pass line.
In another version of the refrigerant circuit, each of the water cooled subsection and the air cooled subsection of the condensing heat exchanger has a refrigerant line in and a refrigerant line out and a by pass line connecting the two and a check valve located downstream of the respective heat exchanger subsection, and wherein a T-junction is located upstream of each heat exchanger subsection, the T-junction being isolated by a pair of solenoid valves for directing flow of refrigerant to the heat exchanger subsection or to the by pass line.
In yet another version of the refrigerant circuit, a header is located downstream of the compressor, the refrigerant flow being split at the header and directed to the water cooled subsection and the air cooled subsection in parallel fashion, and wherein a check valve is located downstream of each subsection, the flow of refrigerant from the respective subsections being recombined in a second header located in the refrigeration circuit.
Preferably, the water cooled subsection and the air cooled subsection are both packaged within a common housing. Most preferably, at least the water cooled subsection is housed within an artistic facade which is selected from the group consisting of water falls and decorative fountains. The artistic facade which houses at least the water cooled subsection can be comprised of a base enclosure and a frame which extends upwardly from the base enclosure, the frame forming an exposed surface or plane for presenting artwork selected by a user of the system. Preferably, the base enclosure houses at least the compressor, the water and air cooled subsections and a receiver. The base can also be provided with an exposed water basin on an upper surface thereof and with the frame supporting selected evaporative cooling media. In this case, the system can further comprise a water source and associated piping for supplying cooling water to the evaporative cooling media, the water being collected downstream in the water basin.
In the method of the invention an air conditioning apparatus is provided wherein a refrigerant is circulated between a condensing heat exchanger and an evaporating heat exchanger in a refrigerant circuit by a compressor. The efficiency of the apparatus is improved by providing both a water cooled subsection and an air cooled subsection in a redundant arrangement as a part of the condensing heat exchanger, and by providing a by pass means for alternately directing the flow of refrigerant in the refrigerant circuit through either or both of the water cooled subsection and the air cooled subsection of the condensing heat exchanger.
In a particularly preferred version of the invention, the system comprises a heat exchanger for an air conditioner system using a combination of air-cooling and water-cooling with appropriate motor controls for adjusting the speeds of the compressor, the condenser water pump and fan and the evaporator fan. The heat exchanger is adapted for use in a typical compressor-condenser-evaporator air conditioning system and specifically to the condenser unit of the system. A networking feature can also be provided to enable such features as system status, statistics gathering and an alarm functionality. A two way communication feature would also allow remote control and configuration.
Additional objects, features and advantages will be apparent in the written description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
The refrigerant based heat exchange system of the invention can be utilized to improve the efficiency of a conventional refrigerant type air conditioning system where a refrigerant such as Freon is circulated by compressor between an evaporator section and a condenser section, wherein it is respectively changed between liquid and gaseous states to effect cooling in the evaporator unit.
The conventional Freon type air conditioning circuit includes a compressor, condenser, a metering device and an evaporator connected in series in a refrigerant circuit. The system is charged with refrigerant, which circulates through each of the components in order to remove heat from the evaporator and transfer heat to the condenser. The compressor compresses the refrigerant from a low pressure superheated vapor state to a high pressure superheated vapor state, thereby increasing the temperature and pressure of the refrigerant. The refrigerant medium leaves the compressor and enters the condenser as a vapor at an elevated pressure. The condenser condenses the refrigerant vapor at substantially constant pressure to a saturated liquid state as a result of the heat transfer in the condenser, typically accomplished with either cooling water or to ambient air. The refrigerant then leaves the condenser as a high pressure liquid. The pressure of the liquid is decreased as it flows through a metering device, such as an expansion type valve, causing the refrigerant to change to mixed liquid-vapor state. The remaining liquid, now at low pressure, is vaporized in the evaporator section of the system as a result of heat transfer from the space being cooled. This vapor then enters the compressor to complete the cycle.
The above described type vapor-compression refrigeration cycle has, for many years, been the pattern for the majority of commercially available air conditioning and refrigeration systems in the marketplace. The present invention is directed to improvements in such systems, and particularly to the condenser sections of such systems.
Turning to
The compressor 11 circulates refrigerant, such as Freon or another suitable compressible refrigerant, between the condensing heat exchanger section 13 and the evaporating heat exchanger 19 in the refrigeration circuit. The receiver 15 stores liquid refrigerant. If multiple condenser modes of the system require multiple refrigerant charges, the receiver acts as a buffer. The receiver 15 also provides storage that may be used at startup when a conventional system would require additional time to build up pressures sufficient to facilitate the required heat exchange.
As will be apparent from
As will be apparent from
In the version of the invention illustrated schematically in
As illustrated schematically in
In the present system, air flows from a source of forced air 53 (for example provided by a fan) to provide a cooling effect over the heat exchange surfaces before being returned as outdoor ambient air 54. To avoid corrosion of the air subsection heat transfer elements (e.g., the air coil), the source of forced air 53 will always be arranged so that the air forced over the water subsystem will never be directed over the air coil. This is accomplished by either having the air subsystem and water subsystem 51, 49 respectively arranged in series as shown in
The previously described refrigerant based heat exchange system can be implemented in any of a number of ways. The following examples are intended to be merely illustrative.
A check valve 77 is located downstream of the respective heat exchanger subsection 69. A T-junction 79 is located upstream of each heat exchanger subsection 69. The T-junction is isolated by a pair of solenoid valves 81, 83 for directing the flow of refrigerant to the heat exchanger subsection or to the bypass line. That is, one of the solenoid valves 81, 83 is normally open while the other is normally closed. Both valves can be connected to the same control signal.
In the system illustrated in
The unit uses a condenser fan 129 to draw air over both the air and water heat exchange media. After passing through the plate-fin condenser/coil 127, the refrigerant returns to the evaporator coil 123 and then back to the compressor 115. A supply fan 131 returns supply air cooled by the evaporator coil. A commercially available TRIAC 133 or other digital controller can be implemented to optimize system efficiency.
The housing 119 is designed to maintain a uniform level of water in the system and the evaporative media (cooling pads) of the system. It can conveniently be designed as a plastic apparatus to keep the water from rusting materials subject to corrosion. In the preferred example shown, the heat exchanger components are incorporated in a plastic apparatus to which a sump pump 135 and a water distributing apparatus 137 are added. A float switch 139 keeps the water level constant. A cut off valve 141 is provided in the water supply line to cut off the water in freezing weather.
The exemplary system can be equipped with a pressure temperature switch (thermostat) and/or humidistat and/or thermister (thermocouple temperature probe) or other controls to control the fan speeds to maintain the appropriate refrigerant pressure. The fan speed is preferably digitally controlled to provide optimum condensation, temperature difference and pressures. A control system using a microprocessor can be provided to manage the mechanical operation of the unit.
This following discussion is intended to be illustrative of a simple control system, which could be used to manage the mechanical operation of the unit.
Inputs:
Float switch or water level sensor to sense water level in the sump basin.
Detection of external thermostat/control system turning the condenser unit on.
A temperature sensor to sense outdoor ambient temperature.
Water Flow Malfunction Detection:
For example a high pressure switch on the hot gas refrigerant. If the water system is failing, the compressor head pressure will rise, signaling to switch to the air subsystem.
Outputs:
Switched output to turn the compressor on and off.
Switched output(s) to start the condenser fan(s).
Switched output to start the water pump.
Switched output to open the fill valve.
Switched output to open a drain valve or drain pump.
Switched output to control water subsystem bypass.
Switched output to control air subsystem bypass.
Alarm Light or Sound Indicator:
Signaling water flow malfunction or other detected problem in the system operation.
Communication:
Optionally, a communication interface that enables the control system to indicate status and alarm conditions to the consumer, facilities manager, or service provider (contractor). This can comprise, for example, an onboard control module using “Blue Tooth,” TCIP, cellular infrared, or other similar technology to provide a communication interface. The type of interface is customer-specific. 802.11 standards are common in most homes today. Energy management and building automation systems may also be used (such as LonWorks, Modbus, Zigbee, etc.)
The above described system is intended to be merely illustrative of a simple control system to manage the mechanical operation of the system. A separate motor controller and fan controller(s) may also be provided.
Preferably, the base enclosure 143 houses at least the compressor (shown as 149 in
The control system for this embodiment of the invention may be implemented in any convenient fashion. For example, a mechanical or electrical float switch (139 in
An invention has been provided with several advantages. The refrigerant based heat exchange system of the invention can be used in a variety of air conditioning and refrigeration type settings to provide improved efficiency, thereby saving on energy costs. By having a condensing heat exchanger with a water cooled subsection which precedes the air cooled subsection, more efficient cooling can be achieved using water for the heat exchange medium. The provision of appropriate bypass means for the subsections allows the water subsection to be diminished or eliminated under selected conditions, for example, in freezing weather. Air flow through the unit is always over the air cooled heat exchange media prior to passing to the water cooled subsection, thereby eliminating the possibility of corrosion or deterioration of the components of the system in contact with tap water or other contaminants. The major components of the system can be housed in a decorative facade which presents a pleasing esthetic appearance for the user. For example, the housing can comprise a decorative waterfall or decorative fountain.
While the invention has been shown in only two of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit thereof.
Claims
1. A refrigerant based heat exchange system, the system comprising:
- a condensing heat exchanger;
- an evaporating heat exchanger connected in a refrigerant circuit;
- a compressor for circulating refrigerant between the condensing heat exchanger and the evaporating heat exchanger in the refrigeration circuit;
- wherein the condensing heat exchanger includes both a water cooled subsection and an air cooled subsection for redundancy; and
- by pass means for selectivley directing the flow of refrigerant in the refrigerant circuit through either or both of the water cooled subsection and the air cooled subsection of the condensing heat exchanger.
2. The refrigerant based heat exchanger of claim 1, wherein the water cooled subsection and the air cooled subsection are located in series in the refrigerant circuit and the water cooled subsection precedes the air cooled subsection.
3. The refrigerant based heat exchanger of claim 1, wherein the water cooled subsection and the air cooled subsection are arranged in parallel fashion within the refrigerant circuit.
4. The refrigerant based heat exchange system, wherein both the water cooled subsection and the air cooled subsection of the condensing heat exchanger include heat exchange surface areas, and wherein air flow from a source of forced air is used to provide a cooling effect over at least the air cooled heat exchange surface area, and wherein the source of forced air is arranged so that the air flow contacts the heat exchange surface area of the air cooled subsection prior to contacting the heat exchange surface area of the water cooled subsection of the condensing heat exchanger.
5. The refrigerant based heat exchange system of claim 4, wherein the water cooled subsection and the air cooled subsection are both packaged within a common housing.
6. The refrigerant based heat exchange system of claim 1, wherein each of the water cooled subsection and the air cooled subsection of the condensing heat exchanger has a refrigerant line in and a refrigerant line out and a by pass line connecting the two and a check valve located downstream of the respective heat exchanger subsection, and wherein a three way valve precedes each subsection for directing flow of refrigerant to the heat exchanger subsection or to the by pass line.
7. The refrigerant based heat exchange system of claim 2, wherein each of the water cooled subsection and the air cooled subsection of the condensing heat exchanger has a refrigerant line in and a refrigerant line out and a by pass line connecting the two and a check valve located downstream of the respective heat exchanger subsection, and wherein a T-junction is located upstream of each heat exchanger subsection, the T-junction being isolated by a pair of solenoid valves for directing flow of refrigerant to the heat exchanger subsection or to the by pass line.
8. The refrigerant based heat exchange system of claim 3, wherein a header is located downstream of the compressor, the refrigerant flow being split at the header and directed to the water cooled subsection and the air cooled subsection in parallel fashion, and wherein a check valve is located downstream of each subsection, the flow of refrigerant from the respective subsections being recombined in a second header located in the refrigeration circuit.
9. A refrigerant based heat exchange system, the system comprising:
- a condensing heat exchanger;
- an evaporating heat exchanger connected in a refrigerant circuit;
- a compressor for circulating refrigerant between the condensing heat exchanger and the evaporating heat exchanger in the refrigeration circuit;
- wherein the condensing heat exchanger includes both a water cooled subsection and an air cooled subsection for redundancy;
- bypass means for selectively directing the flow of refrigerant in the refrigerant circuit through either or both of the water cooled subsection and the air cooled subsection of the condensing heat exchanger; and
- wherein at least the water cooled subsection is housed within an artistic facade which is selected from the group consisting of water falls and decorative fountains.
10. The refrigerant based heat exchange system of claim 9, wherein the artistic facade which houses at least the water cooled subsection is comprised of a base enclosure and a frame which extends upwardly from the base enclosure, the frame forming a plane for presenting artwork selected by a user of the system.
11. The refrigerant based heat exchange system of claim 10, wherein the base enclosure houses at least the compressor, the water and air cooled subsections and a receiver.
12. The refrigerant based heat exchange system of claim 11, wherein the base includes an exposed water basin and wherein the frame supports selected evaporative cooling media, the system further comprising a water source and associated piping for supplying cooling water to the evaporative cooling media, the water being collected downstream in the water basin.
13. In an air conditioning apparatus wherein a compressible refrigerant is circulated between a condensing heat exchanger and an evaporating heat exchanger in a refrigerant circuit by a compressor, the method of improving the efficiency of the apparatus comprising the steps of:
- providing both a water cooled subsection and an air cooled subsection in a redundant arrangement as a part of the condensing heat exchanger; and
- providing a by pass means for selectively directing the flow of refrigerant in the refrigerant circuit through either or both of the water cooled subsection and the air cooled subsection of the condensing heat exchanger.
14. The method of claim 13, wherein the water cooled subsection and the air cooled subsection are located in series in the refrigerant circuit and the water cooled subsection precedes the air cooled subsection.
15. The method of claim 13, wherein the water cooled subsection and the air cooled subsection are arranged in parallel fashion within the refrigerant circuit and wherein a control valve is located in the refrigerant line ahead of each subsection, the valves being operable to selectively direct refrigerant to the respective water and air cooled subsections.
16. The method of claim 13, wherein both the water cooled subsection and the air cooled subsection of the condensing heat exchanger are provided with heat exchange surface areas which are cooled by air from a forced air source, and wherein the source of forced air is arranged so that the air flow forced over the heat exchange surface area of the water cooled subsection never contacts the heat exchange surface area of the air cooled subsection.
Type: Application
Filed: Feb 17, 2006
Publication Date: Aug 17, 2006
Inventor: Eric Barger (Plano, TX)
Application Number: 11/356,777
International Classification: F25B 39/04 (20060101);