Condensate collection system, arrangement, and method

Abstract

A condensate collection system or arrangement for use in combination an energy recovery system of a paint booth arrangement comprises upper and lower baffle arrangements axially staggered relative to one another. The upper baffle arrangement comprises a series of parallel, diversion structures, and the lower baffle arrangement comprises a series of parallel trough structures. The trough structures are staggered relative to the diversion structures such that an upwardly directed air stream is directed through the trough and diversion structures into the energy recovery system. Condensate, formed via the energy recovery system, is directed from the energy recovery system through spacing the diversion structures into the trough structures. The trough structures are in fluid communication with a common outlet that directs the condensate stream away from the condensate collection system. Certain condensate collection methodology is further contemplated.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to a condensate collection system or arrangement. More particularly, the present invention relates to a condensate collection system or arrangement for use in combination with a heat recovery module of a ventilated paint booth arrangement, which condensate collection system collects condensate from the heat recovery module and directs the condensate stream away from critical paint booth components.

2. Brief Description of the Prior Art

Paint booths are used to enclose certain dangerous activities that are performed therein (such as painting and stripping) and to contain the risk of fire. Paint booths are further utilized to control the overspray from the spray paint guns and capture the paint particles that are not applied to the object being painted. Paint booths are designed in accordance with local and national electrical and fire codes and are usually surrounded with single or double skinned walls.

A critical component of paint spray booths is the ventilation system. The exhaust air flow rates may be determined by paint transfer efficiency of the spraying operation, protection of personnel from exposures to harmful chemicals, and maintaining a concentration of flammable vapors in the exhaust system that is well below the lower flammability limit.

Paint spray booths also utilize conditioned air for quality of the painted surface and operator comfort. Air flow volumes can be very large and a significant amount of energy goes into conditioning the air that passes through the paint spray booth. In these applications there may be an opportunity to recover some the energy that is leaving the system as heated air in the exhaust.

One of the design issues that must be considered is that in the process of recovering heat from the exhaust, condensation of the humidity in the exhaust air stream is formed. The level of condensation is dependent upon a variety of factors such air relative humidity, exhaust air flow rate, and heat recovery device surface temperatures. If uncontrolled this condensate can damage filters, cause rusting of the spray booth enclosure, and create potential health and safety issues. Some of the more pertinent prior art relating to air conditioning systems and/or condensate collection systems and the like are briefly described hereinafter.

U.S. Pat. No. 3,522,841 ('841 Patent), which issued to Papalexious, discloses a Constant Volume Air Heating and Cooling Unit. The '841 Patent describes an air supply conditioning unit of the constant volume air heating and cooling type comprising air foil shaped dampers at the outlet ends of the heat exchanger and free air passages to regulate the amount of air passing through each. The unit maintains a constant volume of air flow and efficiently blends the various streams of existing air without causing undue turbulence. The airflow is divided by V-shaped damper assemblies, the angle of which V-shaped assemblies may be reduced or enlarged for controlling airflow thereby.

U.S. Pat. No. 3,618,659 ('659 Patent), which issued to Rawal, discloses an Environmental Conditioning System and Method. The '659 Patent describes an environmental conditioning method for removing stale air and replacing it, at least in part, with fresh air at volumetric rates that are substantially the same. The stale air from the room is delivered to a return damper with a kinetic energy level of substantially zero, and the volumetric rate of airflow from and to the room is substantially independent of the volume of air removed and replaced. A modular damper unit (with adjustable damper assemblies) may be employed, which provides heat exchangers for conservation of heat energy, and the system provided is readily adapted for centralized, overall environmental conditioning by the incorporation of heating, cooling, cleaning and humidity control means therein.

U.S. Pat. No. 3,926,249 ('249 Patent), which issued to Glancy, discloses an Energy Recovery System. The '249 Patent describes a method and apparatus to recover energy from used or foul air and to return the energy into fresh air to reduce the energy input to a ventilation system. Ventilator apparatus is adapted to maintain fluid flow through a first heat exchanger, positioned in a fresh air passage, and through a second heat exchanger, positioned in an exhaust passage, at a controlled rate to afford maximum or controlled heat transfer efficiency for pre-cooling or pre-heating fresh air drawn into the system. Control apparatus is provided to maintain flow of fluid through the heat exchangers such that the sum of the mass flow of fresh air times the specific heat of the fresh air, plus the mass flow of the exhaust air times the apparent specific heat of exhaust air, is equal to two times the mass flow of fluid times the specific heat of the fluid.

U.S. Pat. No. 4,000,779 ('779 Patent), which issued to Irwin, discloses a Blowoff Baffle. The '779 Patent describes a condensate guide arranged in the path of a flow of air through an A-coil heat exchanger including slabs oriented generally horizontally relative to the air flow. The condensate guide is positioned downstream of the heat exchanger so that condensate when blown from the surface of the heat exchanger by the air flow therethrough impinges on the guide thereby removing it from the path of air and directing it to an appropriate drain.

U.S. Pat. No. 4,537,120 ('120 Patent), which issued to Josefsson, discloses a Surface Treatment Plant and a Method of Ventilating Same. The '120 Patent describes a paint spray booth enclosure having separate zones defined by air curtains, one zone being polluted differently than another. A separate flow of ventilating air is passed through each zone. Each zone has its own separator for cleaning exiting air of its pollutant. In the illustrated embodiments, the outer zones have dry separators and the central zone has a wet separator. Suitable conduits permit total or partial recirculation of the cleaned air, or total exhaust of the air to the atmosphere. Fresh outside air may be supplied to the ventilating flows along with spent ventilating air from the plant. Suitable controls for the air are provided.

U.S. Pat. No. 4,616,594 ('594 Patent), which issued to Itho, discloses a Painting Booth. The '594 Patent describes a painting booth in which an appropriate temperature and humidity control is effectively performed for that zone in the painting chamber in which the object to be painted is conveyed, for enabling a drastic reduction in the amount of energy required for such temperature and humidity control, as compared with a conventional painting booth within which such control is performed for the whole painting chamber.

U.S. Pat. No. 4,778,493 ('493 Patent), which issued to Martin et al., discloses a Gasification Reactor with Internal Gas Baffling and Liquid Collector. The '493 Patent describes a gasifier having a combustion chamber in which a hydrocarbonaceous fuel is burned to produce a usable gas. A quench chamber is positioned to receive said gas and other byproducts as an effluent stream, in a coolant liquid quench bath. A dip tube and draft tube define a tortuous passage within a quench chamber for directing the gaseous segment to a discharge port by way of said quench bath. A baffle positioned in the path of the gas includes a manifold at the baffle lower end to receive condensate which flows from said baffle face and returns water to the quench bath.

U.S. Pat. No. 5,030,805 ('805 Patent), which issued to Koenig et al. discloses a Condensation Heating Apparatus. The '805 Patent describes a condensation heating apparatus particularly useful for curing abrasion resistant coatings on eyeglass lenses has an open topped chamber with a baffle assembly for reducing the loss of vapor through the open top. The baffle assembly includes a fixed vertical partition and a removable, L-shaped baffle that has a horizontal portion to cover part of the chamber and a vertical portion which also serves as a partition. The baffle assembly extends only partially into the chamber and terminates above the top of the vapor zone so that the assembly does not become hot to the touch.

U.S. Pat. No. 5,913,360 ('360 Patent), which issued to Stark, discloses a Dual Pass Cooling Plate Type Cross Flow to Air Heat Exchanger with Air Flow Damper Control. The '360 Patent describes a heat exchanger for dehumidifying an air stream including heat conducting plates which serve as the heat exchange surface for precooling and reheating the air during the dehumidification process. Cooling conduits are positioned in a plane parallel to a plane defined by the heat conducting plates, such that cooling occurs in the intake air stream and heating occurs in the exhaust air stream, and the air flow is redirected in a small plenum chamber located at an end of the channels adjacent to the cooling conduits. A system is also provided which includes a plurality of heat exchangers joined edge corner to edge corner sharing a common cooling coil and a common plenum chamber. The heat exchange system includes a fan for conducting air through the heat exchangers and through the cooling coil, a manifold assembly which includes an intake damper, exhaust damper, and baffle dampers, and a cooling damper disposed in a condensate collection chamber.

U.S. Pat. No. 6,241,009 ('009 Patent), which issued to Rush, discloses an Integrated Heat Pipe Vent Condenser. The '009 Patent describes an integrated heat pipe vent condenser having a vent condenser casing surrounding one or more heat pipes in a vapor duct of the heat pipe steam condenser. The casing may be provided at an inclined orientation relative to a vertical axis of the heat pipe steam condenser. A plurality of baffles is positioned within the casing to provide a serpentine path for a vapor flow entering the casing from the vapor duct to pass through. Condensable gases from the vapor flow condense on the heat pipes and baffles and condensate is drained back into the vapor duct for removal through a drain or downcomer having a trap to prevent vapor flow from entering the downcomer.

U.S. Pat. No. 6,675,746 ('746 Patent), which issued to Gerstmann et al., discloses a Heat Exchanger with Internal Pin Elements. The '746 Patent describes a heat exchanger/heater comprising a tubular member having a fluid inlet end, a fluid outlet end and plurality of pins secured to the interior wall of the tube. Various embodiments additionally comprise a blocking member disposed concentrically inside the pins, such as a core plug or a baffle array. Also disclosed is a vapor generator employing an internally pinned tube, and a fluid-heater/heat-exchanger utilizing an outer jacket tube and fluid-side baffle elements, as well as methods for heating a fluid using an internally pinned tube.

U.S. Pat. No. 7,059,385 ('385 Patent), which issued to Moilala, discloses an Air Conditioning Device. The '385 Patent describes a invention consisting of recovery cells, inlet and exhaust ducts leading to and from a room, inlet and exhaust ducts located at the other end of the device and leading to and from the outdoor air, the air flows in the air conditioning device being controlled by means of rotating deflectors. The deflectors consist of baffles fixed to different control axes and rotating about their axes, the air openings provided in the deflectors being located at the same recovery cell, where the air flow directions are reversed periodically.

U.S. Pat. No. 7,185,513 ('513 Patent), which issued to Bush et al., discloses a Low Profile Evaporator Coil. The '513 Patent describes an assembly located between a heating furnace and a plenum. The assembly includes multiple coil slabs through which a refrigerant courses. The slabs lie in a parallel relationship at an angle of inclination to the air entering a coil assembly. A baffle is associated with each coil slab to constrain air flow through the associated coil slab. A drain pan is positioned beneath the slabs. The drain pan has multiple troughs for collecting condensate. At least some of the multiple troughs have an air foil that reduces air flow restriction.

U.S. Pat. No. 7,600,489 ('489 Patent), which issued to Lomax, Jr. et al., discloses a Heat Exchanger Having Plural Tubular Arrays. The '489 Patent describes a heat exchange apparatus including a housing, and first and second arrays of fluid conduits provided within the housing. The first and second arrays of fluid conduits are configured to carry a first fluid. The heat exchange apparatus also includes a first fluid passageway provided within the housing, where the first fluid passageway is defined by an internal surface of the housing and by a baffle plate. The first fluid passageway is configured to carry a second fluid. The baffle plate is configured to divide the first fluid passageway into a first flow path and a second flow path, where the first array of fluid conduits extends through the first flow path and the second array of fluid conduits extends through the second flow path.

United States Patent Application Publication No. 2005/0150756, which was authored by Stout, describes a horizontal shell encompassing a plurality of effects and a series of vertical compound baffles fastened to the horizontal shell and dividing it into a series of pressure-tight chambers. Each chamber along with its associated apparatus constitutes an effect. Each compound baffle comprises a fixed baffle and a removable baffle. A heat exchanger is fastened to the removable baffle and includes an evaporation surface, a condensation surface, and a pressure chamber isolated from the pressure-tight chamber in which it is located. A port in the compound baffle allows evaporate to pass between the pressure chamber and the pressure-tight chamber of an adjacent effect. The shell is provided with a removable top plate to provide access to the heat exchanger and allow removal of the heat exchanger and removable baffle.

From a consideration of the foregoing, it will be noted that the prior art perceives a need for a condensate collection system and/or arrangement cooperable with an air handling unit or air makeup unit (AMU) for collecting and capturing relatively heavy streams of condensate that fall from heat or energy recovery portions of the AMU, which condensate collection system comprises lower and upper baffle arrangements that sequentially function to divide an upwardly drive air stream while said upper and lower baffle arrangements sequentially divert and collect a falling condensate to as to controllably direct the ensuing condensate stream away from critical portions of a paint booth arrangement.

SUMMARY OF THE INVENTION

A primary objective of the present invention is to capture and controllably direct condensate streams being pulled from air makeup units made part of a paint booth installation. Notably, in cases of extreme cold weather or extreme warm weather, it may be desirable to include an energy recovery device (such as plate heat exchanger, glycol runaround coils, or heat wheel) to recover from the energy or heat that is exhausted that would be normally wasted. In this case air from the outside may preferably pass through a heat exchanger that transfers heat to the exhaust in the summer and takes heat from the exhaust in winter.

The present invention provides a condensate capturing or collecting arrangement for use in combination with paint spray booths having energy recovery feature(s). In other words, the invention relates to paint spray booths that utilize energy recovery in the form of heat recovery from the exhaust stream(s) of the paint spray booth. The process of heat recovery generates condensate in the heat recovery device which if unabated would collect in the exhaust plenum causing possible damage and health and safety issues. The invention is intended to be used where the paint spray booth design necessitates the need to have vertical air flow up toward the heat recovery device.

The invention is a device that collects the falling condensate while allowing for the air to pass through the device with the minimum amount of air flow resistance. In the direction of air flow the first or lower set of baffles divide the air into a first series of air sub-streams. These same baffles form the trough structures that collect the falling condensate and direct the condensate stream(s) to a common collection point or outlet for the assembly.

The second set or upper set of baffles that the air stream encounters is formed to direct the air toward gaps into a second series of air sub-streams that are directly above the first or lower set of baffles. It is through these gaps that the condensate falls through as the droplets become large enough that they are no longer suspended by the upward movement of the air.

The size of the invention is based upon available space, paint spray booth exhaust flow rate, and desired pressure drop allowing flexibility of design to meet the requirements of specific paint spray booths while maintaining the principles that allow this device to accomplish the collection of the condensate.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features of my invention will become more evident from a consideration of the following brief description of patent drawings:

FIG. 1 is a detailed right side elevational type depiction of a prior art paint booth arrangement (1) usable in combination with a condensate collection arrangement according to the present invention, or (2) in which a condensate collection arrangement according to the present invention may be utilized.

FIG. 2 is a fragmentary, enlarged right side elevational type depiction of the rear portion of an exemplary paint booth arrangement (1) usable in combination with a condensate collection arrangement according to the present invention, or (2) in which a condensate collection arrangement according to the present invention may be utilized.

FIG. 3 is a top perspective view of a prior art air intake-exhaust complex of the paint booth arrangement otherwise depicted in FIG. 1, in which laterally opposed air makeup units are supported by said complex further outfitted with exhaust ducts and a centralized, louvered air intake assembly for directing air into the air intake chambers of the air intake-exhaust complex.

FIG. 4 is a diagrammatic side view type depiction of the generalized airflow path through the prior art paint booth arrangement otherwise depicted in FIG. 1, which generalized airflow path is depicted in two dimensions.

FIG. 5 is a fragmentary, enlarged, right side diagrammatic type depiction of the rear end of an exemplary paint booth arrangement parts of which have been removed to more clearly show the structural relationship of the condensate collection arrangement according to the present invention relative to said rear end.

FIG. 6 is a fragmentary, enlarged, right side diagrammatic type depiction of the upper portion of rear end otherwise shown in FIG. 5 with parts broken away to more clearly show the structural relationship of the condensate collection arrangement according to the present invention relative to said rear end.

FIG. 7 is a fragmentary, detailed depiction of the bottom portion of an energy recovery cell as sectioned from an air makeup unit as juxtaposed in superior adjacency to opposed condensate collection arrangements according to the present invention.

FIG. 8 is a side view of a condensate collection arrangement according to the present invention showing an upper baffle arrangement juxtaposed in superior adjacency to a lower baffle arrangement, both of which baffle arrangements are angled or sloped relative to a horizontal plane.

FIG. 9 is an end view of the condensate collection arrangement according to the present invention showing an axially staggered structural relationship of the upper baffle arrangement to the lower baffle arrangement.

FIG. 10 is a top perspective exploded view of left and right portions of a condensate collection arrangement showing the upper and lower baffle arrangements thereof.

FIG. 11 is a top perspective view of the lower baffle arrangements of opposed condensate collection arrangements according to the present invention.

FIG. 12 is a diagrammatic end view type depiction of airflow through the condensate collection arrangement according to the present invention.

FIG. 13 is a diagrammatic end view type depiction of condensate flow through the condensate collection arrangement according to the present invention.

FIG. 14 is an enlarged, fragmentary an diagrammatic end view type depiction of the upper baffle arrangement juxtaposed in superior adjacency to the lower baffle arrangement of the present invention, further depicting collected condensate flowing out of the page.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings with more specificity, the preferred embodiment of the present invention concerns a condensate collection arrangement, the primary use for which is in combination with a paint booth structure and/or arrangement as exemplified by the arrangement otherwise described in U.S. Pat. No. 7,666,077, issued Feb. 23, 2010 to Thelen (i.e. the '077 Patent), the specification(s) of which are hereby incorporated by reference thereto.

FIGS. 4(a), 13, and 14 of the '077 Patent are respectively reproduced in this specification and supporting illustrations as FIGS. 1, 3, and 4 and marked as PRIOR ART. FIG. 2 is a fragmentary, enlarged depiction of the rear end of an exemplary paint booth arrangement 10 to depict the relative placement of the condensate collection system 50 relative to an exemplary paint booth arrangement 10 so as to aid the reader is his or her understanding of the present invention.

In this last regard, and as is noted in the '077 Patent, paints booths for painting air craft and the like may be said to essentially comprise an equipment-enclosing structure and certain air handling equipment specifically associated and configured for cooperative use with the equipment-enclosing structure. Most typically, the equipment enclosing structure essentially constitutes a hangar type building and comprises a forward section 12; a rearward section 13; laterally opposed wall sections 14; and a centralized roof section 15. The '077 Patent further disclosed certain laterally opposed wall-to-roof sections (as at 16 in said patent), which wall-to-roof sections defined certain in-line ductwork for directing airflows of the air handing equipment.

In other words, the paint booth arrangement of the '077 Patent places bulky air handling equipment in line with the otherwise unoccupied space defined by the wall-to-roof sections, which sections function to configure the non-uniform roof structure as means to aid the cross draft airflow as at 105. It is contemplated that the condensate collection arrangement 50 according to the present invention operates on the basis of having a minimum collector-based airflow velocity of 1800 to 2400 feet per minute while airflow rates through the paint booth are preferably on the order of 50-100 feet per minute. Booth-based airflow rates falling below this latter velocity range may well operate to extract vapors, but may not be sufficient to carry particulates within paint overspray to the airflow exhaust filters as at 11. It is thus contemplated that airflow velocity is a critical factor highly indicative of the symbiotic relationship between the equipment-enclosing structure and air handling equipment of a paint booth.

If, by way of further example, air handling equipment is placed in line with unoccupied space otherwise defined by non-uniform roof structures (which structure is designed for enhancing cross draft air flow 105 as in the '077 Patent), more efficient use of paint booth space can be achieved. Portions of the air handling equipment according to the present invention are thus preferably placed in line with the non-uniform roof structures, including an air intake assembly, an air exhaust assembly, and an air replacement system all of which are in communication with one another.

Outside fresh air is taken into the system via ducts 22, which inlet airflow is directed downwardly as at 101. Once the outside air enters an air intake plenum (not specifically illustrated), it is divided or diverted laterally into filter banks 21. As the filtered airflow leaves the filter banks 21, the airflow is directed upwardly as at 102 to dual air handling units or air makeup units (AMU's) 30.

Notably, an AMU is a device typically used to condition and circulate air as part of a heating, ventilating, and air-conditioning (HVAC) system. Usually, an AMU is housed within a large metal box containing a blower, certain heating and/or cooling elements, filter racks or chambers, sound attenuators, and dampers. In this case, it is contemplated that in addition to the foregoing, the AMU's 30 may preferably comprise certain heat or energy recovery means or systems for maximizing efficient use of thermal energy passing through or within the paint booth arrangement 10.

It is further contemplated that the heat or energy recovery means may be exemplified by such devices as plate heat exchangers, glycol runaround coils, or heat wheels to recover energy that is taken in or exhausted as heat that would otherwise be untapped. As earlier stated, airflows may pass through a heat exchanger, which heat may transfer to the exhaust in warmer summer time temperatures, and be drawn from the exhaust in cooler winter timer temperatures. Energy savings from this type of system require that ducts from the exhaust and supply systems interconnect.

If the AMU is located remotely from the paint booth, the interconnecting ducts can be very large and space-occupying. Indeed, state of the art air handling systems typically incorporate remote mounting of air handlers, which require said large space-occupying ducts. The present invention places the AMU's 30 in close proximity to exhausting airflows and no such ducting is otherwise required, thereby maximizing space efficiency.

It is contemplated that the AMU's 30 according to the present invention may preferably comprise a fresh or outside air intake section 24, an energy recovery cell section 25, and a blower section 29 for supplying air to ductwork 32 for further supplying the plenum doors 19 with horizontally directed airflow 103. Downwardly directed airflow 104 within the plenum doors 19 is then directed (as at 105) into the open space 106, which horizontally directed or cross draft airflow 105 opposes airflow 103 for carrying overspray particulates and vapor toward certain exhausting means at or adjacent the rearward section 13.

The exhaust assembly usable in combination with the condensate collection arrangement 50 preferably comprises a three stage National Emissions Standards for Hazardous Air Pollutants (NESHAP) filtration system or air exhaust complex 40. Cross draft airflow 105 from the open space 106 of the booth arrangement 10 enters the complex 40 via the filters 11 and exits the complex 40 via the heat or energy recovery cells 25 in further communication with exhaust ducts 41 having exhaust fans 42 housed therewithin for further enhancing exhaust as at 108 of airflow from the booth arrangement 10.

From a careful consideration of the drawings, it should be noted that the ducts 41 are assembled in communication with the energy recovery cell sections 25 so that energy may be recovered from exhausting airflows, particularly airflow 107 as it is circulated to airflow 103. Energy recovery is common in systems having exhaust components, a portion of the energy of which is transferred from the system to its surroundings. Some of the energy in that exhaust may be transferred to the intake or inlet airflow. Basic thermodynamic principles dictate that a temperature differential allows heat transfer and thus energy transfer, or in this case, energy recovery.

In systems involving heat transfer, certain vapor condensing means may operate to condense a substance from its gaseous to its liquid state, typically by cooling it. In so doing, the latent heat is given up by the substance, and will transfer to the condenser coolant. In this case, the heat or energy recovery cells 25 comprise certain vapor condensing means for condensing water vapor into liquid water droplets, which droplets fall (under gravitational pull) and are collected and redirected by the condensate collection arrangement 50 according to the present invention so as to prevent (a) damage to filters, (b) rusting of the spray booth enclosure, and (c) potential health and safety issues, to name just a few benefits.

The present invention may thus be said to provide certain air conditioning means having condensate collection means for use in combination with a paint booth arrangement, which condensate collection means preferably comprises certain vapor-condensing means and a condensate collection arrangement for reducing the humidity of a circulating air stream and/or recovering energy from the airflow(s) 107/103. The vapor-condensing means are capable of forming weighty, water-based condensate 110 from water vapor in a circulating air stream 107/103 within the heat or energy recovery cells 25.

Accordingly, the condensate collection arrangement 50 is preferably positioned in inferior adjacency to said vapor-condensing means 115 for collecting a condensate stream 111 therefrom. The condensate collection arrangement 50 preferably comprises an upper baffle arrangement 51 and a lower baffle arrangement 52. The upper baffle arrangement 51 comprises a series of parallel, diversion structures 53, each of which comprise a substantially diamond shaped transverse cross-section. The lower baffle arrangement 52 is positioned in inferior adjacency to the upper baffle arrangement 51 and preferably comprises a series of parallel trough structures 54, each of which comprise a substantially V-shaped transverse cross-section.

It may be seen from an inspection of the various figures, that the trough structures 54 are preferably and axially staggered relative to the diversion structures 53 such that the air stream 107 is respectively directed through (1) spacing 112 intermediate the trough structures 54, and (2) spacing 113 intermediate the diversion structures 53 into the vapor-condensing means 115 of the cells 25 as generically or diagrammatically depicted by a box in broken lines. The condensate collection stream 111 is respectively directed from the vapor-condensing means 115 of the cells 25 through (1) spacing 113 intermediate the diversion structures 53 into the trough structures 54. The trough structures 53 are in fluid communication with a common outlet 55 for directing the condensate stream 111 away from the condensate collection arrangement 50. The diversion structure(s) 53 and the trough structure(s) 54 are angles relative to the horizontal plane (as at 114) so as to allow collected condensate 116 to flow toward the outlet 55. Conduit leading from the outlet(s) 55 for directing the stream to an appropriate disposal site is not specifically illustrated.

Being respectively and preferably diamond-shaped and V-shaped in transverse cross section, the diversion structures 53 and trough structures 54 each preferably comprise V-shaped lower surfacing as at 56. It is contemplated that the V-shaped lower surfacing 56 well function to reduce turbulence in the air stream 107 as said stream 107 proceeds through the arrangement 50. Further, the diversion structures 53 preferably comprise inverted, V-shaped upper surfacing as at 57 and the trough structures 54 comprise upright, V-shaped upper surfacing as at 58. The V-shaped upper surfacing (as at 57 and 58) functions to enhance or direct flow of the condensate stream 111 toward the common outlet 55.

The inverted, V-shaped upper surfacing 58 further preferably comprises condensate stream-diverting termini as at 59. The condensate stream-diverting termini 59 are in parallel upper baffle planes as at 117. The upper baffle planes 117 of adjacent diversion structures 53 have substantially uniform upper baffle spacing 118. Further, the upright, V-shaped upper surfacing 58 comprises condensate stream-receiving termini 60, which condensate stream-receiving termini 60 are in parallel lower baffle planes 119. The lower baffle planes 119 of respective trough structures have lower baffle spacing as at 120. The upper baffle spacing 118 is less than the lower baffle spacing 120 for enhancing or directing condensate stream flow from the diversion structures 53 into the trough structures 54.

The diversion structures 53 preferably comprise channel walls 61 intermediate the V-shaped lower surfacing 56 and the inverted, V-shaped upper surfacing 57. The channel walls 61 are coplanar with the upper baffle planes 117, and the channel walls 61 of adjacent diversion structures 53 thereby form a channel zone 121 for directing the condensate stream 111 into the trough structures 54. The channel walls 61 further preferably comprise drip breaks 62 adjacent the V-shaped lower surfacing 56. The drip breaks 62 of adjacent diversion structures 53 are angled toward one another for directing the condensate stream 111 into the trough structures 54. In this regard, it is contemplated that the channel zone 121 may be narrowed by the drip breaks or breakers 62 of the upper baffle arrangement for directing falling condensate into narrowed conduit sub-streams as at 125.

Each trough structure 54 is capable of collecting and directing four (4) gallons of water per minute toward the outlet 55, and the arrangement 50 is well able to collect falling condensate density up to 9.5 gallons per hour per square foot. In view of the relatively high amount of condensate 110, a significant amount of splashing effect is often encountered as diagrammatically depicted at 122 in FIG. 14. In this regard, it is contemplated that the arrangement may further preferably comprise a series of parallel splash plates 63. The splash plates 63 extend intermediate the diversion structures 53 in superior adjacency to the trough structures 54 for directing splash 122 from the inverted, V-shaped upper surfacing 57 into the trough structures 54. In other words, errant condensate 110 may be re-directed into the condensate stream(s) 111 while falling by way of the splash plates 63. The splash plates may be provided with stiffener structure 64 for maintaining planes 123.

While the above description contains much specificity, this specificity should not be construed as limitations on the scope of the invention, but rather as an exemplification of the invention. For example, as is described hereinabove, it is contemplated that the present invention essentially discloses a condensate collection arrangement 50 for directing a condensate stream as exemplified by stream 111 away from an air stream as exemplified by stream 107. The condensate collection arrangement 50 may be said to essentially comprise an upper baffle arrangement and a lower baffle arrangement staggered relative to the upper baffle arrangement.

The upper baffle arrangement as at 51 comprises a series of parallel, diversion structures as at 53, and the lower baffle arrangement as at 52 is positioned in inferior adjacency to the upper baffle arrangement 51 and comprises a series of parallel trough structures 54. The trough structures 54 are axially staggered relative to the diversion structures 53. The air stream is respectively directed (i.e. directed in sequence) through spacing intermediate the trough structures 53 and diversion structures 54, while the condensate stream is respectively directed (i.e. directed in sequence) from the air stream (by way of certain vapor condensing means) through spacing intermediate the diversion structures 53 into the trough structures 54. The trough structures 54 are in fluid communication with a common condensate stream outlet as at 55.

In addition to the foregoing structural considerations, it is further believed that the inventive concepts discussed support certain new methods and/or processes for directing air stream and for collecting and directing a condensate stream within a paint booth arrangement. In this regard, it is contemplated that the detailed specifications support a certain process for directing said streams, which directed streams may well function to enhance operational efficiency of a paint booth operation. The process may be said to comprise a series of steps as perhaps most clearly reflected in FIG. 14, and as supported by the structures and depictions in the remaining illustrations.

The methodology may thus be described as a method for directing a condensate stream away from a directed air stream, and may be said to include the steps of: directing a vapor-laden air stream in an upward, first direction (as at 107) respectively or in sequence through a lower baffle arrangement and an upper baffle arrangements. Condensate 110 may then be formed from the upwardly directed vapor-laden or humid air stream in superior adjacency to the upper baffle arrangement.

The condensate 110 is allowed to fall in a downward, second direction (as at 111) opposite the first direction (as at 107) toward the upper baffle arrangement at which it is diverted into parallel condensate sub-streams as at 125. The parallel condensate sub-streams 125 are then directed into the lower baffle arrangement thereby collecting the parallel condensate streams 125, whereafter the collected condensate sub-streams 125 are directed away from the air stream in a third direction (as at vector arrows 130 directed out of the page in FIGS. 13 and 14) via the lower baffle arrangement.

The method may be said to comprise the further step of axially staggering the lower baffle arrangement relative to the upper baffle in a direction orthogonal to the first and second directions before directing the vapor-laden air stream in the upward, first direction. From a comparative inspection of FIG. 13 versus FIG. 14, it will be seen that the lower baffle arrangement 52 and upper baffle arrangement 51 are staggered left-to-right across the page which left-to-right direction is orthogonal to an upward direction as at 107 and a downward direction as at 111.

The method may further comprise the step of dividing the upwardly directed humid or vapor-laden air stream into a first series of parallel air sub-streams as at 126 via the lower baffle arrangement while directing the air stream in the upward, first direction. The first series of parallel air sub-streams may then be divided into a second series of parallel air sub-streams 127 via the upper baffle arrangement while directing the air stream in the upward, first direction. In other words, the second series of parallel air sub-streams 127 may be formed by dividing the first series of parallel air sub-streams 126 via the upper baffle arrangement while directing the vapor-laden air stream in the upward, first direction.

Accordingly, although the invention has been described by reference to certain preferred embodiment(s) and certain methodology, it is not intended that the novel arrangement and methods be limited thereby, but that modifications thereof are intended to be included as falling within the broad scope and spirit of the foregoing disclosures and the appended drawings.

Claims

1. A condensate collection system for use in combination with a paint booth arrangement, the condensate collection system comprising:

vapor condensing means for condensing vapor in a circulating air stream into condensate; and

a condensate collection arrangement, the condensate collection arrangement being positioned in inferior adjacency to said vapor condensing means for collecting a condensate stream therefrom, said condensate collection arrangement comprising upper and lower baffle arrangements, the upper baffle arrangement comprising a series of parallel, diversion structures, the lower baffle arrangement being positioned in inferior adjacency to the upper baffle arrangement and comprising a series of parallel trough structures, the trough structures being axially staggered relative to the diversion structures, the air stream being sequentially directed through spacing intermediate the trough structures and diversion structures into space surrounding the vapor condensing means, the condensate stream being sequentially directed from the vapor condensing means through spacing intermediate the diversion structures into the trough structures, the trough structures being in fluid communication with a common outlet, the common outlet for directing the condensate stream away from the condensate collection system.

2. The condensate collection system of claim 1 wherein the diversion and trough structures each comprise V-shaped lower surfacing, the V-shaped lower surfacing for reducing turbulence in said air stream.

3. The condensate collection system of claim 2 wherein the diversion structures comprise inverted, V-shaped upper surfacing and the trough structures comprise upright, V-shaped upper surfacing, said inverted and upright V-shaped, upper surfacing for enhancing direction of the condensate stream toward the common outlet.

4. The condensate collection system of claim 3 wherein the inverted, V-shaped upper surfacing comprise condensate stream-diverting termini, the condensate stream-diverting termini being in parallel upper baffle planes, the upper baffle planes of adjacent diversion structures having upper baffle spacing, the upright, V-shaped upper surfacing comprising condensate stream-receiving termini, the condensate stream-receiving termini being in parallel lower baffle planes, the lower baffle planes of respective trough structures having a lower baffle spacing, the upper baffle spacing being less than the lower baffle spacing for enhancing condensate stream direction from the diversion structures into the trough structures.

5. The condensate collection system of claim 4 wherein the diversion structures comprise channel walls intermediate the V-shaped lower surfacing and the inverted, V-shaped upper surfacing, the channel walls being coplanar with the upper baffle planes, the channel walls of adjacent diversion structures thereby forming a channel zone for directing the condensate stream into the trough structures.

6. The condensate collection system of claim 5 wherein the channel walls comprise drip breaks adjacent the V-shaped lower surfacing, the drip breaks of adjacent diversion structures being angled toward one another for directing the condensate stream into the trough structures.

7. The condensate collection system of claim 3 comprising a series of parallel splash plates, the splash plates extending intermediate the diversion structures in superior adjacency to the trough structure for directing splash from the inverted, V-shaped upper surfacing into the trough structures.

8. A condensate collection arrangement for directing a condensate stream away from an air stream, the condensate collection arrangement comprising:

an upper baffle arrangement, the upper baffle arrangement comprising a series of parallel, diversion structures; and

and lower baffle arrangement, the lower baffle arrangement being positioned in inferior adjacency to the upper baffle arrangement and comprising a series of parallel trough structures, the trough structures being axially staggered relative to the diversion structures, the air stream being sequentially directed through spacing intermediate the trough structures and diversion structures, the condensate stream being sequentially directed from the air stream through spacing intermediate the diversion structures into the trough structures, the trough structures being in fluid communication with an outlet.

9. The condensate collection arrangement of claim 8 wherein the diversion and trough structures each comprise V-shaped lower surfacing, the V-shaped lower surfacing for reducing turbulence in said air stream.

10. The condensate collection arrangement of claim 9 wherein the diversion structures comprise inverted, V-shaped upper surfacing and the trough structures comprise upright, V-shaped upper surfacing, said V-shaped upper surfacing for enhancing direction of the condensate stream toward the outlet.

11. The condensate collection arrangement of claim 10 wherein the inverted, V-shaped upper surfacing comprise condensate stream-diverting termini, the condensate stream-diverting termini being in parallel upper baffle planes, the upper baffle planes of adjacent diversion structures having upper baffle spacing, the upright, V-shaped upper surfacing comprising condensate stream-receiving termini, the condensate stream-receiving termini being in parallel lower baffle planes, the lower baffle planes of respective trough structures having a lower baffle spacing, the upper baffle spacing being less than the lower baffle spacing for enhancing condensate stream direction from the diversion structures into the trough structures.

12. The condensate collection arrangement of claim 10 wherein the diversion structures comprise channel walls intermediate the V-shaped lower surfacing and the inverted, V-shaped upper surfacing, the channel walls being coplanar with the upper baffle planes, the channel walls of adjacent diversion structures thereby forming a channel zone for directing the condensate stream into the trough structures.

13. The condensate collection arrangement of claim 12 wherein the channel walls comprise drip breaks adjacent the V-shaped lower surfacing, the drip breaks of adjacent diversion structures being angled toward one another for directing the condensate stream into the trough structures.

14. The condensate collection arrangement of claim 8 comprising a series of parallel splash plates, the splash plates extending intermediate the diversion structures in superior adjacency to the trough structure for directing splash from the diversion structures into the trough structures.

15. A method for directing a condensate stream away from a directed air stream, the method comprising the steps of:

directing a vapor-laden air stream in an upward, first direction sequentially through lower and upper baffle arrangements;

forming condensate from said directed air stream in superior adjacency to the upper baffle arrangement;

allowing formed condensate to fall in a downward, second direction opposite the first direction toward the upper baffle arrangement;

diverting falling condensate into parallel condensate streams via the upper baffle arrangement;

directing the parallel condensate streams into the lower baffle arrangement, thereby collecting the parallel condensate streams; and

directing the collected condensate streams away from the air stream in a third direction via the lower baffle arrangement.

16. The method of claim 15 comprising the step of axially staggering the lower baffle arrangement relative to the upper baffle in a direction orthogonal to the first and second directions before directing the air stream in the upward, first direction.

17. The method of claim 16 comprising the step of dividing the upwardly directed air stream into a first series of parallel air sub-streams via the lower baffle arrangement while directing the air stream in the upward, first direction.

18. The method of claim 17 comprising the step of dividing the first series of parallel air sub-streams into a second series of parallel air sub-streams via the upper baffle arrangement while directing the air stream in the upward, first direction.

19. The method of claim 17 comprising the step of forming a second series of parallel air sub-streams from the first series of parallel air sub-streams via the upper baffle arrangement while directing the air stream in the upward, first direction.

20. The method of claim 15 comprising the step of re-directing errant condensate into the condensate streams while diverting falling condensate.

21. A condensate collection method, the method comprising the steps of:

allowing condensate to fall in a first direction toward an upper baffle arrangement;

diverting falling condensate into condensate streams via the upper baffle arrangement;

directing the condensate streams into a lower trough arrangement, thereby collecting the condensate streams; and

directing the collected condensate streams in a second direction via the lower trough arrangement.

22. The method of claim 21 comprising the step of axially staggering the lower trough arrangement relative to the upper baffle arrangement in a direction orthogonal to the first direction.

23. The method of claim 22 comprising the step of channeling the directed condensate streams into a series of parallel condensate sub-streams via the upper baffle arrangement while diverting falling condensate into condensate streams.

24. The method of claim 23 comprising the step of narrowing the channeled condensate sub-streams via breakers of the upper baffle arrangement while diverting falling condensate into condensate streams.

25. The method of claim 21 comprising the step of re-directing errant condensate into the condensate streams while diverting falling condensate.